重庆市跨座式轨道交通PC梁生产工艺流程指导书

目录

第一部分 灌前············································································································ 2

一、 台车放线及放线精度要求··········································································· 2

1、底模台车放线···························································································· 2 2、底模台车精度控制要求及放线质量要求················································ 2 二、支座安装及精度要求····················································································· 3

1、支座安装···································································································· 3 2、支座安装质量要求···················································································· 5 三、端模板安装及其精度质量要求····································································· 5

1、端模制作安装···························································································· 5 2、端模控制精度要求和安装质量标准························································ 7 四、钢筋制作及安装及验收标准········································································· 8

1、钢筋制作安装···························································································· 8 五、内模制作安装······························································································· 13

1、内模制作·································································································· 13 2、在上个工序中按图纸将内模吊装入钢筋骨架内·································· 14 3、内模安装施工质量控制要求·································································· 15 六、预应力管道及钢束安装··············································································· 16

1、波纹管安装······························································································ 16 2、钢束安装·································································································· 16 3、波纹管安装质量要求·············································································· 17 七、侧模安装······································································································· 18

1、模板调整·································································································· 18 2、合模·········································································································· 19 3、侧模调整质量要求·················································································· 21

第二部分 灌中············································································································ 21

一、混凝土原材料要求······················································································· 21

1、原材料遵循的技术条件·········································································· 21 2、水泥·········································································································· 21 3、细骨料······································································································ 21 4、粗骨料······································································································ 22 5、外加剂······································································································ 23 6、水·············································································································· 23 二、混凝土搅拌及输送······················································································· 24

1、混凝土搅拌······························································································ 24 2、混凝土的输送·························································································· 25 3、炎热季节及冬季施工·············································································· 25 三、混凝土灌注工艺··························································································· 26

1、混凝土浇灌······························································································ 26 2、振捣·········································································································· 26 3、抹面·········································································································· 26

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第三部分 灌后·········································································································· 27

一、养护··············································································································· 27

1、蒸汽养护·································································································· 27 2、自然养护·································································································· 28 二、脱模··············································································································· 28

1、脱模要求·································································································· 28 2、脱模顺序·································································································· 29 3、脱模后PC梁表面修饰··········································································· 29 三、尺寸检测······································································································· 30

1、检测器具·································································································· 30 2、外形尺寸·································································································· 30 四、预应力张拉··································································································· 35

1、张拉前准备工作及注意事项·································································· 35 2、第一批张拉工艺······················································································ 37 3、需重新张拉情况······················································································ 38 4、第二批张拉······························································································ 38 5、张拉安全注意事项·················································································· 38 五、封锚··············································································································· 39 六、压浆··············································································································· 39

1、预应力孔道压浆的重要性······································································ 39 2、真空辅助压浆·························································································· 40 3、材料、设备检验或检查·········································································· 42 4、配合比的试拌及各项指标······································································ 42 5、真空辅助压浆施工工艺·········································································· 43 6、压浆施工注意事项·················································································· 45 七、封端··············································································································· 46

1、浇筑封端混凝土前准备工作·································································· 46 2、封端·········································································································· 46 3、封端后养护及处理·················································································· 47 八、吊梁、存梁工序··························································································· 47

1、起重设备·································································································· 47 2、移梁安全操作规程·················································································· 49 3、存梁操作规程·························································································· 49 4、双层存梁·································································································· 50

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第一部分 灌前

一、 台车放线及放线精度要求 1、底模台车放线

1）台车放线前先对底模台车进行清理。 2）平面直线梁（含带竖曲线的平面直线梁）

a）用钢卷尺及钢直尺放出台车的横向中心线及纵向中心线，并标记。 b）以台车纵向中心线作为梁跨中心线，然后根据轨道制作工法指导书，计算出安装好后台车活动面端部到支座中心纵向中心两端和梁体边线(端模）的距离，以此放支座及端模位置。

3）平面曲线梁（含带竖曲线的平面曲线梁）

a）以台车纵向中心线作为梁跨中心线。用钢直尺标记出台车中心向台车纵向中心线两侧相同距离(425mm)，并向台车两端做平行线，然后根据PC轨道梁制作工法指导书，计算出安装好后台车活动面端部到支座纵向中心两端点和梁体边线（端模）的弦长距离，以此放出端模及支座位置。

b）再用钢直尺量出支座横向中心线两端点到台车横向中心线的垂直距离复核支座位置。

c）以上两步骤也可同时进行，相互复核工法指导书中的放样数据以达到放样的精确性。

2、底模台车精度控制要求及放线质量要求

1）精度控制要求

a）顶面不平整度≤2mm/m2；

b）轮对中心线与台车顶面中心线重合，误差≯10mm； c）活动平台之间及活动平台与车体接缝（顶面）≯3mm； d) 活动小车顶面与车体顶面应在同一平面，允许误差≤1mm； e）顶面与行走钢轨面高差允许误差±3mm。

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2）放线质量要求

按表1-1-1进行检查验收 表1-1-1 序号 1 2 3 检验项目 全长 梁跨 梁宽 标准 ±2mm ±2mm ±1mm 检测工具 钢卷尺、拉力器 钢卷尺、拉力器 钢卷尺 检查频次 全检 全检 抽检两端、L/4、L/2、3L/4共无处 4 底部预埋件 ±2mm 钢卷尺 、拉力器、刚直尺 全检 检查数量：按每榀梁检查 检查方法：检查放线记录

二、支座安装及精度要求 1、支座安装

1）安装支座前核对型号和安装位置准确无误。

a）支座分为四类：即直线固定支座、直线活动支座、曲线固定支座、曲线活动支座。

直线固定支座正面 直线固定支座侧面 直线活动支座正面 直线活动支座侧面

曲线固定支座正面 曲线固定支座侧面 曲线活动支座正面 曲线活动支座侧面 b）支座安装位置应严格按照轨道梁制作工法指导书操作。曲线梁支座安装时应注意支座的大截面端应安装于曲线外侧，小截面端应安装于曲线内侧。

2）支座安装步骤

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a）首先在台车上拉一根细线与台车纵向中心线重合。

b）将龙门吊将支座吊装到钢支座调整机构支架上，使支座的横向中心线与台车中心线重合。再将支座上摆调平使顶面的纵横向中心线（纵横向中心线应由支座厂商在支座上刻注）分别与下摆横纵中心线重合，并将支座调平。

调节支座中心线与台车中心线重合 调节支座呈水平

c）根据台车放样数据调节支架纵移机构将支座调到梁跨横向中心线支座中心位置，再用螺栓固定调整机构的固定端使其整个调整机构固定牢固。

d）调节横移机构螺杆和角度调整机构螺杆，根据台车放样计算数据，活动面端部到支座纵向中心线两端距离调节支座纵向中心位置及偏移角度，精确定位并固定。

测量活动面到支座中心距离

e）用水准仪检查支座顶面与台车顶面的高差。

水准仪检测高差

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