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1、 高速铁路非标准简支梁施工工法中铁十八局集团有限公司桑松龄 栾兆增 曹海清1 前言随着近几年高速铁路的大发展，在京沪高速铁路建设中，桥梁占到正线长度的86.5%，而桥梁中多数为简支梁桥，绝大多数的标准简支梁在梁场利用定型钢模板在梁场预制，而非标准梁因跨度不一，若采用预制梁，将加大施工生产成本。沧德特大桥该段桥地震动峰加速度为0.1g，场地类别为类。我工区承担的后张法预应力混凝土简支箱梁为沧德特大桥B29B30号墩、B57B58及C68-C69号墩之间的非标梁。其中，B29B30号墩箱梁计算跨度为19.5m，B57B58号墩箱梁计算跨度为30.8m, C68-C69号墩箱梁计算跨度为29.8m。
2、该段简支箱梁均位于直线上，且地势较为平坦，梁体混凝土强度为C50。箱梁结构形式设计为单箱单室等高简支梁，梁端顶板、底板及腹板局部向内侧加厚，在结构外侧的腹板与顶底板相交处均采用圆弧倒角过渡 。梁高3.05m，底宽为5.5m，梁顶宽12.0m。在腹板上设100mm的通风孔，底板上设90mm的泄水孔。2工法特点2.1搭设满堂支架作箱梁底板支撑系统；2.2内模采用木模。内模采用10槽钢作支撑骨架分节拼装，骨架之间接头采用斜法兰连接，拆卸方便。模板采用3.5cm厚木板，在内模骨架的顶面与侧面安装木板与骨架通过螺栓固定后，再在木板表面上包裹地板革作为内模的面层。内模底部不安装模板，主要考虑底板混凝土入模
3、与振捣方便。2.3利用全站仪、电子水准仪等仪器对桥面六面坡及桥梁外缘进行精确定位，确保桥梁的整体线形。3适用范围适用于平原地区非标准简支桥梁施工。4工艺原理采用搭设满堂支架作箱梁底板支撑系统，原位现浇法施工工艺，底板、腹板与顶板一次性浇筑成型。5施工工艺流程及操作要点5.1 总体施工工艺流程地基加固、硬化处理场地平整搭设满堂支架做混凝土试件kuai件第二次预应力张拉、压浆，封锚第一次预应力张拉、压浆、养护安放石屑袋沉降观测混凝土拌和运输钢 筋 加 工拆底模和支架拆内模、拆侧模与端模养 护浇注混凝土安设各种预埋件、预留孔绑扎顶板钢筋安装内模与端模绑扎底、腹板钢筋，安波纹管卸载、安装底模侧模支架预
4、压图51现浇箱梁施工工艺流程图5.2 满堂支架施工5.2.1、基础处理碗扣式满堂支架搭设前须进行基底处理。具体做法为：将原地表土挖除1m深，然后分层回填，并用压路机压实，之后填筑40cm厚10灰土填筑压实；每层压实厚度不少于20cm，利用18振动压路机分层碾压。碾压稳定后，观测表面平整、无轮痕，再通过试验进行检测。处理后的地基高出原地面不小于20cm，并做成不小于2的单面或双面坡，以便于下雨时排水顺畅。满足支架地基设计承载力要求后，在支架基础四周挖好排水沟，作好排水系统。5.2.2、搭设支架现浇箱梁采用满堂碗扣支架搭设。(1)支架布置碗扣式满堂支架布置示意图详见满堂支架布设图。1、箱梁中部(底
5、板与腹板等截面部分)：立杆按纵向步距60cm、横向步距60cm，水平横杆竖向间距120cm设置。2、箱梁端部（梁端底板与腹板加厚部分）：立杆纵向步距60cm、横向步距60cm，水平横杆竖向间距120cm设置。3、箱梁翼缘板部：立杆纵向步距90cm、横向步距90cm，水平横杆竖向间距120cm设置。经检算上述布置原则满足承重支架横杆、立杆验算要求，将支架搭设具体方法，详细交底至施工队。5.2.3、支架预压试验考虑梁体自重、地面下沉及支架的弹性和非弹性变形等因素影响，需对支架进行预压。预压采用砂袋预压，在梁体底模方木上或临时木板上采用1.2倍梁体自重的砂袋进行支架预压。在预压范围内，四周用袋装沙子
6、围挡，中部用钢材。钢材的分布尽量与梁各部自重成比例。测点布设：每跨纵桥向设5个断面(约间隔5m设1个)，每个断面设10个测点，上下各5个，上部5个测点分别设在两侧翼缘板各1个、两腹板处各1个，梁中心线底板处1个；下5个测点分别设在对应上5个的水平投影位置左右，并且在枕木上。对各测量点进行编号，以便预压时进行对比观测，控制模板立模标高。Opinions and suggestions on the partys mass line educational practiceAccording to the central and provincial, municipal unified depl
7、oyment, according to municipal Party committee about carrying out the partys mass line educational practice activity in the citys implementation opinions, the spirit of the partys mass line educational practice activities from 20* in January to 99 months, carried out at all levels of departments and
8、 directly affiliated institutions and grass-roots party organizations. According to my actual County, the county to carry out the education practice put forward the following implementation opinions.First, the overall requirementsCounty county education practice to the eighteen Party of eight, the s
9、pirit of the the third Plenary Session of the 18th CPC Central Committee as the guidance, conscientiously implement the spirit of general secretary Xi Jinping book series of important speech, earnestly implement the Central Committee really, opinions and advice , party implementing the guiding ideol
10、ogy of opinions to determine the objectives and requirements, step method, in accordance with the look in the mirror, dress up, wash bath, cure treatment, the general requirements of for the people pragmatic honest people as the theme, in carrying forward the spirit of Zhuanglang Zhuang, improve the
11、ir work style, service to the masses of the people, the foundation of consolidating grassroots, promote transformation across efforts, to further implement the central eight regulations and The opposition party and government austerity waste regulations , double section provincial regulations, munic
12、ipal provisions of the twelve plan and the implementation measures for on improving the work style of close ties with the masses law, highlight style building, carry out the whole wind spirit, resolutely oppose formalism, bureaucracy, hedonism and wasteful extravagance to solve the problems, Party m
13、embers and cadres of the style and the masses of people strong, the Ministry of Party members and cadres to further improve their thinking and understanding, to further change the style of the wind, the masses to close, honest and pragmatic people honest image to further establish the foundation to
14、further reinforce the basic level. Style of the building of the new results to promote the construction of a powerful force of the county and the ecological culture of the county and county construction.In educational practice activities of the unit is mainly: the county and below county departments
15、 under the organs, enterprises and institutions directly under the township, street, and community, village, non-public economic organizations, social organizations and other grass-roots organizations. Agencies and branches, each single unit, follow the rules on internal institutions. Educational pr
16、actice with step by step.To adhere to the county leadership, leadership and leading cadres to focus on outstanding catch to directly contact the service of the masses of law supervision departments and window units, service industry, educational practice, pay attention to grasp the heavy towns, stre
17、ets and villages, community education activities and the masses of grassroots groups in close contact to strengthen, and the majority of Party members, cadres and the mass line line Marx doctrine view of the masses and the partys education.Always speak seriously as a basic attitude, adhere to positi
18、ve education, to carry out criticism and self criticism group, adhere to the pragmatic, more emphasis on leadership, pay more attention to the layers of the demonstration, more focus on the four winds, solve the problem, pay more attention to open the door, the participation of the masses, pay more
19、attention to the classification guidance. Orderly, pay more attention to the cooperation and cohesion driven, more strict requirements on injection, really supervision practice, ensure education practice is not empty is not empty is not partial, not as a mere formality.Two, the key point of the task
20、The main task of the countys education practice is to seize against four wind this focus on centralized solve outstanding problems asked County, township leadership and leading cadres of the four winds, the disadvantages of the style, scale behavior to a large scale investigation, overhaul, cleaning
21、 greatly. At the same time, respond to the concerns of the masses, safeguard the interests of the masses, pay attention to solve practical problems, solve the people around the unwholesome tendencies especially on eat, take the card, Yong lazy luxury, extravagance and waste fees, privileges and othe
22、r issues, timely and effective, without any discount to solve, to improve the style of real implementation of the requirements of real to the grassroots, real let group Benefit the public.(a) focus on solving the four winds outstanding issuesThe central and provincial requirements, the county leader
23、ship and leading cadres of key performance concept is not correct, do not dare to play, to engage in image project, political project, a leadership guide, a set of ideas, orders and prohibitions, and a policy, there are countermeasures county. The units directly under the heavy focus on solving Yung
24、 lazy drag, buck passing skin, work is not implemented, the service is not active. The dynamic problem of law enforcement and supervision departments and window units, service industry mainly solve the door hard, ugly face, something difficult, and arbitrary charges, fines, levies, and breach of pri
25、vilege, chinakayao, not the problem of law. The township, street The collar of leading bodies and leading cadres to solve key does nottheir own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness
26、, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the c
27、ompetitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resour
28、ces, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attrac
29、t injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business,
30、firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigor
31、ously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt t
32、o the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy
33、, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development.7以30.8m跨非标梁为例，按照支架检算荷载进行堆载预压，两侧梁端中部各3m范围内均布堆载154t；箱梁中间22.9m*6m范围内均布堆载456t；两侧翼缘板31.9m*3m范围内各均布堆载95.7t。观测按加载前、100荷载、120荷载加载后24小时进行。通过预压，消除支架的非弹性变形、基础沉降变形，并获得弹性变形值，为模板铺设的标高与预拱度的设置提供数据。预
34、应力混凝土简支箱梁根据不同跨度、混凝土收缩徐变以及预计二期荷载等因素而定。根据设计要求，30.8m跨的箱梁预设反拱16.56mm，预设反拱时，必须严格按计算好的数据控制好各部支架的标高，确保预拱度符合要求。5.2.4模板设计与安装模板的好坏是现浇箱梁质量好坏的关键，模板必须有足够的强度和刚度，保证使用周转次数多，不变形、不破损。1、 模板设计与加工(1)侧模侧模采用大块定型组合钢模板，由专业生产厂家加工制作。侧模面板采用热轧钢板，面板背后采用钢板设置强度较大的纵横向加强肋，同时采用槽钢作支撑骨架，骨架各部连接以及骨架与加强肋均采用满焊形式，有力地保证了整体刚度与稳定性。垫石施工支座安装（2）底
35、模底模采用15mm厚的高强覆膜竹胶合板，由专业生产厂家生产，选定固定供应商统一供货到现场，在由施工队伍按照设计图现场裁剪与加工。（3）内模内模采用木模。内模采用10槽钢作支撑骨架分节拼装，骨架之间接头采用斜法兰连接，拆卸方便。模板采用3.5cm厚木板，在内模骨架的顶面与侧面安装木板与骨架通过螺栓固定后，再在木板表面上包裹地板革作为内模的面层。内模底部不安装模板，主要考虑底板混凝土入模与振捣方便。（4）端模端模采用木模。根据梁的腹板与底板处的锚具所在的位置不同，由于尺寸多样，形式复杂，端模应分块做成，组合拼装，主要由底板、腹板、翼缘板和顶板分块组合。2 模板安装顺序侧模底模 (绑扎底、腹板钢筋)
36、内模(绑顶板钢筋) 端模翼缘板顶侧模。5.2.5 钢筋及钢绞线加工与安装普通钢筋及钢绞线加工时抓住四个环节：1、钢绞线与钢材的试验（物理试验与化学试验）；2、钢材和钢绞线严格下料尺寸；3、钢筋焊接严把质量关；4、钢筋按图加工成平面和立体骨架；5、分层、分号进行钢束编束和穿束；6、准确定位预应力波纹管。内模加工侧模安装内模安装预应力管道定位成型5.2.6箱梁混凝土的浇注与养护箱梁混凝土标号为C50，采用一次浇筑成型。混凝土拌和采用拌和站集中生产，混凝土搅拌输送车运输现场，采用混凝土输送泵车泵送入模。1混凝土浇筑（1）、浇筑混凝土前，对模板、加固支架进行全面检查，波纹管、锚垫板、喇叭管、螺旋筋位置
37、要准确，定位要牢固，不要遗漏接触网支柱、防撞墙、电缆槽、支座等各种预埋件以及泄水孔和排气孔等预留孔道的预埋工作。（2）、混凝土浇筑：混凝土浇筑采用两台混凝土输送泵车，从一端向另一端浇筑，两台泵车分别负责浇筑底板腹板与顶板，一前一后，保持一定的距离。浇筑采用斜向分段，水平分层的方法连续浇筑。浇筑混凝土顺序：横向先腹板与底板交角处腹板下中部底板腹板中上部顶板，循序渐进一次浇筑完成。（3）、腹板振捣采用插入式振捣器。梁箱与腹板钢筋密集，又有波纹管，空隙小，宜采用长30cm的小振捣器，其它处可采用大振捣器。振捣上一层混凝土时，应插入下一层混凝土510cm，振捣时以混凝土表面不再显著下沉，表面泛出灰浆为
38、止。不得过振，也不能漏振。特别是顶面高程要严格控制，振捣密实，压实抹平。振捣时要注意不触及波纹管和锚具，混凝土浇筑过程中要派专人检查模板、固定螺栓和满堂支架是否有松动和脱落和漏浆现象，如有异常情况，必须停止浇筑混凝土，抓紧处理。 针对波纹管最低处，密集处，锚头处要派专人加强振捣，必要时换成30cm振捣棒振捣，特别在振捣到预埋管及预埋件处要小心细致振捣，确保位置准确密实。（4）、顶面混凝土边浇筑，边人工整平，边人工收浆，控制梁顶各部标高及返水坡坡度。待混凝土达到能够站人时便开始用磨光机对梁面进行初磨，随着表面平整度加强与梁面强度增高，逐渐开始精磨。磨光机不易磨到的部位，配合人工抹平、压光。磨面结
39、束后便开始混凝土养护工作。 2 砼养生紧随整平与收浆后，立即覆盖塑料薄膜保水，整平与收浆结束，薄膜覆盖完成。顶面混凝土磨面结束后，覆盖湿土工布，之后再覆盖一层塑料布，保证顶面混凝土的保温保湿条件。侧模、内模与端模不能急于拆除，同时作好测温工作，及时掌握混凝土芯部、表面与环境的温差，保证芯部与表面、表面与环境的温差不大于15。砼养生5.2.7 预应力筋张拉与压浆钢束的张拉是预应力混凝土工程的关键工序，直接影响到工程的质量，必须严格按照施工操作规程进行。成立专业的张拉队伍，指定专人负责，每次张拉前都对所有设备进行一次检查，确定是否按标定的标号配套使用。张拉前应计算每根钢束的理论伸长值。预应力张拉过
40、程中采用油表读数和张拉力双控。孔道压浆采用真空压浆方法。5.2.8 施工注意事项1、支架架设前对支架基础进行处理，以保证支架在坚实的地基上。2、每孔支架进行预压，以获得充分的技术参数。3、以腹板防崩钢筋作为定位钢筋，在直线段每隔100cm布置一组。4、预应力管道采用波纹管成形，严格控制管道坐标及弯曲角度，在曲线段加强管道的定位钢筋以保证管道顺畅。5、待现浇箱梁混凝土强度达到设计强度的100后，张拉预应力钢束。张拉时实行引伸量和张拉吨位“双控”，引伸量误差控制在6%范围内。6、在每一道施工缝处，对张拉完后的钢束进行管道压浆，压浆工作连续进行，不得中断，以确保压浆质量。三 施工总结及效果非标梁的施
41、工重点是对其线形及桥面六面坡的控制，全站仪测量控制，从施工情况来看，有很好的效果。其次是混凝土内外质量的保证，除试验上加强控制外，混凝土的振捣也很关键，采用专职振捣人员，取得了不错效果，混凝土内实外美，得到了一致好评。 采用桥位现浇施工方法,保证了施工工期和质量。为全段的按期竣工打下了良好的基础。而且为同类工程施工积累了经验。并证明了本施工方法在非标梁施工中是适用的。6材料与设备主要施工机械设备表 机械名称规格型号额定功率（KW）或容量（m3）或吨位（t）单位数量装载机ZL503M3台1挖掘机WY800.8m3台1振动压路机YZ1818t台1平板振动夯HZR1205kw台1汽车起重机QY252
42、5t台1混凝土输送泵车60m3/h台2张拉设备YCK3000300台套4灰浆搅拌机UJW32.2kw台2真空压浆泵SZ-22 m3/h台套2插入式振捣器ZH-502.2KW台20插入式振捣器ZX-301.1KW台8钢筋切割机GJ40-140mm台5电焊机BX-30030KW台10钢筋切断机台4钢筋弯曲机台4箱梁模板厂家生产套17质量控制7.1 执行的相关质量标准与验收规范本工程施工主要依据铁道第三勘察设计研究院设计的桥梁施工图纸、客运专线铁路桥涵工程施工技术指南TZ213-2005、铁路桥涵钢筋混凝土和预应力混凝土结构设计规范TB10002.3-2005,铁路桥涵工程施工质量验收标准TB101
43、45-2003.。8安全措施8.1安全技术措施8.1.1司吊人员必经国家安检部门考试合格持证上岗。1、施工期不断对司吊人员安全知识培训与考核，加强操作人员的安全意识。8.1.2. 吊机司机在操作起重过程中因注意事项。1、起吊前对钢丝绳以及吊机设备进行检查，确保起重机在完好状态下可靠地有效地工作，在操作中严格执行安全技术规程，不发生任何人身和设备事故；2、吊机司机在了解掌握电动机的机械性能的基础上，根据吊物的具体情况正确操作控制器 ；3、应做到起重机司机“十不吊”。8.1.3.司索指挥人员作业中应做到。1、对吊点起吊前要认真检查牢固性 ；2、对使用的吊具索具要认真检查合理使用；3、对于锐角工具要
44、有包角处理；4、对司机的指挥信号要明确清晰。8.2临时用电的安全技术保障措施。8.2.1凡是电工作业人员必须持证上岗，杜绝无证操作。8.2.2断电作业必须挂有明显警示标志8.2.3施工现场用电要做到三级控制两极保护。8.2.4施工现场临时用电的外电架设必须执行46-2005用电规范要求，做好外电防护。8.2.5施工现场的机械设备要保证一机一闸一漏保一箱。8.2.6临时专用闸箱的架设安装，按规范要求架设不能低于1.3米。8.3高空作业安全措施8.3.1高空作业的人员要求身体健康，凡患有高血压、心脏病等不适于高空作业人员，不得从事高空作业，空中作业必须系好安全带和工具袋，安全带系于牢固之处，工具放
45、在袋中，不准乱抛、乱放，以防掉下伤人。8.3.2地面操作人员，尽量避免在高空作业的正下方停留或通过，也不得在起重机的吊杆和正在吊装的构件下停留或通行。8.4、特种作业管理特殊工种作业人员（包括电工、电焊工、架子工、起重工、工程车辆司机、指挥人员等）首先进行专业技术培训，按规定到有关主管部门经考试合格后，持证上岗。认真审查特种作业人员的操作证件是否有效，无证的人员禁止上岗。特种作业必须严格执行各种安全技术操作规程，确保安全施工。特种作业人员安全生产教育：特种作业人员除进行一般安全教育外，还要经过本工种的安全技术教育，经考核合格发证后，方准独立操作。9环保措施9.1文明施工具体要求1、保持现场整洁
46、，保证卫生要求，合理安排临时设施，存放和处置好设备及材料，及时清运垃圾，在施工活动中，实施清洁生产工艺，减少废物产生量，对施工过程中产生的废料，如焊条头、废钢铁等进行分类堆放，然后进行标识，定期回收处理。2、工程完工后,及时清除设备、材料、垃圾及各种临时设施，并保持施工现场和工程清洁整齐。10应用实例沧德特大桥(DK228+305DK238+470.17段)非标梁工程由中铁十八局集团第五工程有限公司承建，该工程2009年3月16日开工，2009年5月15日竣工。该工法已在沧德特大桥工程中得到实际应用，已顺利通过监理部验收，该桥性能指标达到设计要求，由于新技术、新工艺的应用，使该进步桥工程取得了显著的经济效益和社会效益，积累的满堂支架、内箱龙骨制作、线性控制等方面技术，对今后我国同类型高速铁路桥非标梁的结构设计、施工具有参考和指导意义，为促进我国高速铁路非标梁桥的发展具有很高的推广应用价值。19