Simulation Experiment Research on the Production of Large Box Girders
Abstract
:1. Introduction
2. Beam Yard Production Process and Process Time
2.1. Process
- (1)
- Rebar cage lashing: This includes steel bar processing, beam body steel bar binding, and hoisting, where steel bar binding is the process with the largest workload, which takes the most time and the most manpower. The beam reinforcement binding and hoisting process includes steel bar split binding and secondary hoisting. Then, the steel bar is bound as a whole and hoisted once, before being split and tied, and hoisted once after being installed as a whole. Then, the split binding of steel bars and one-time hoisting with inner molds are carried out. After the reinforcement of the prefabricated beam body of the box girder is tied, it needs to be hoisted to the beam-making pedestal via a gantry crane.
- (2)
- Formwork technology: The box girder formwork is divided into the bottom form, outer form, inner form, and end form. The formwork sub-project construction technology is mainly influenced by the steel bar sub-project production technology and the method of moving the beams. The bottom form and outer form are mostly fixed, and the steel bar cage is installed after the inner form is lifted. Finally, the end form is installed and the model is adjusted.
- (3)
- Concrete pouring: The concrete pouring process for the beam directly affects the quality of the box beam, requiring continuous pouring and one-time forming. During construction, strict control must be exercised over the delivery, mixing, pouring, and vibration of the concrete. The operation must be monitored throughout to ensure that the concrete strength and related quality indicators are met.
- (4)
- Concrete curing: The primary purpose of concrete curing is to ensure the appropriate temperature and humidity during the solidification process of the concrete. Different curing methods are chosen based on varying climatic conditions. In summer, the method of natural curing using curing blankets is mainly employed to maintain the moisture of the concrete and prevent surface cracking. In winter, steam curing is primarily used to ensure the proper temperature and humidity for concrete solidification, thus preventing the temperature from being too low during the initial setting and ensuring that the internal temperature of the concrete does not become too low or too high during the constant temperature curing period.
- (5)
- Prestressed construction: The prestressing of box girders generally consists of the following stages: initial prestressing, preliminary prestressing, and final prestressing. The initial and preliminary prestressing stages occur during the construction of the beam platform, while the final prestressing stage is performed on the storage platform after the required age has been met. After the prestressing of the box girder is completed, subsequent procedures such as grouting of the ducts are carried out.
- (6)
- Transportation of box girders from the beam production platform: The initial prestressing of the precast box girder can only begin when the concrete strength of the girder meets over 80% of the design requirements. To achieve timely cycling of the formwork and the beam production platform, the box girder is moved from the production platform to the storage platform according to the technical specifications. It will continue to undergo natural curing while waiting for the strength and age requirements for final prestressing to be met. The transportation of the box girder is primarily carried out using gantry cranes and wheeled girder lifters.
2.2. Production Process Time Data Distribution
3. Establishment of the Simulation Model of Box Girder Production
3.1. Model Establishment
3.2. Model Parameter Settings
- (1)
- The time system of the beam field simulation model is 24 h a day.
- (2)
- Processes 1, 5, and 7 are the operation of steel bar binding, the work intensity of this process is large, and the work progress that has been carried out is not affected when the operation is started again after the operation is suspended. Thus, the preempt scheduling rule is adopted, that is, the point is off work, the operation can be continued after going to work, and the quality of work is not affected.
- (3)
- For the other 12 kinds of processes, once started, if they are stopped before they are completed, the quality of the project will be affected. Thus, the ignore scheduling rule is adopted, that is, once the process starts, it must be completely completed before it can be completed.
- (4)
- Process 10, concrete curing, adopts the uniform distribution (UNIF) assumption, as shown in Figure 3, according to the actual situation, and the process is not subject to the working time system.
- (5)
- The operation time for the other processes is estimated by the field engineer for the most probable time, the most pessimistic time, and the most optimistic time and processed into a triangular distribution (TRIA), as shown in Figure 4 (taking the bottom web reinforcement binding as an example).
- (6)
- According to the actual situation, it is assumed that the supply of resources for the non-direct process is sufficient, and there will be no downtime and waiting due to resource shortage, especially in the concrete pouring process, which strictly requires the continuity of pouring.
- (7)
- Because the production process between different beam-type concrete beams is basically the same, but there is a time difference in the beam-type production process technology. Because the number of 24 m beams in the research beam field is not much, this paper ignores the beam type difference in this study, and the 32 m beam is taken as an example for simulation test research.
4. Verification of Simulation Results
5. Beam Field Production Simulation Experiment
5.1. Simulation Research of Traditional Production Methods
5.2. Research on the Production Simulation of the Steel Bar Pre-Binding Method
5.3. Research on the Production Simulation of the Intelligent Beam Field
- (1)
- Prestressed automatic tensioning system: The prestressed synchronous automatic tensioning construction technology is adopted, the manual operation is changed to mechanical automatic control, and the equipment operation is started with one key. Automatic measurements, synchronous control, accurate data, and timely checking are used to realize multi-top synchronous tensioning, reduce the construction period, improve work efficiency, and reduce labor input (one whole box girder only needs to be configured with five to six people).
- (2)
- Smart templates: The intelligent hydraulic template realizes the functions of automatic walking positioning, automatic leveling, automatic overall lifting, translation of the outer mold through the intelligent control system, and the functions of automatic opening of the inner mold, automatic rotation of the lower chamber, and automatic walking. Intelligent hydraulic formwork is generally equipped with a monitoring system, including a laser ranging sensor, horizontal inclination sensor, rope displacement sensor, etc., to ensure the efficiency and accuracy of formwork installation.
- (3)
- Smart fabric: Intelligent distribution is the use of intelligent equipment to pour concrete evenly on the prefabricated component template and automatic vibration process. An intelligent distribution machine is generally composed of a control system, a distribution system, a vibration system, and a monitoring system.
- (4)
- Smart maintenance: The intelligent maintenance system of a precast beam yard is generally composed of a high-pressure water pump, induction temperature measurement, automatic controller, etc. This equipment automatically perceives the temperature and humidity of the beam and the environment, realizes unmanned, intelligent, and refined spray maintenance in accordance with the intelligent spray algorithm and maintenance specifications, improves the maintenance quality, and greatly reduces the maintenance time.
6. Conclusions
- (1)
- In the traditional beam yard, the beam-making cycle of the beam-making pedestal is usually about eight days. In the ultimate state, the beam-making cycle of the pedestal can be shortened by 44.5%. In addition, the sensitivity analysis of the daily working time of the beam yard shows that when the working time system increases from 8 h/d to 12 h/d, the average occupation time of the beam-making pedestal is shortened by 11.5 h when the working time system is extended by 1 h. When the working time system changes from 12 h/d to 24 h/d, the average occupancy time of the beam-making pedestal is shortened by 3.43 h when the working time system is extended by 1 h/d per day. Thus, the sensitivity coefficient of the extended working time in the early stage is significantly greater than that in the later stage. This quantitatively gives the changes in the beam-making cycle of the pedestal under different time systems, allowing the beam yard manager to adjust the working hours to achieve the desired production efficiency and, at the same time, avoid the unnecessary cost increase caused by blind overtime.
- (2)
- Under the normal operation of the beam yard, the steel bar pre-binding method increases the beam-making efficiency of the beam yard by 43.9%, but in the extreme production state of the beam yard, the steel bar pre-binding method increases the beam-making efficiency of the beam yard by 21.3%. Thus, with the extension of the working time system, the advantages of the steel bar pre-binding method gradually decrease. This shows that the method improves the beam-making efficiency to a certain extent, but this is realized by separating the reinforcement binding process. The reinforcement pre-binding method does not fundamentally change the operation time of the beam-making process, so it results in a very limited improvement in the beam-making efficiency.
- (3)
- The application of intelligent technology greatly improves the production efficiency of the beam field, and this improvement is gradually increased with the extension of the working time system. Thus, with the extension of the daily working time, the advantages of the intelligent beam field become more obvious. This shows that the production of the intelligent beam field is more efficient. In addition, the production process of the beam field is more flexible and the ability to resist risks is stronger.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Serial Number | The Name of the Operation | Time Distribution (h) |
---|---|---|
1 | Base plate and web rebar binding | TRIA (12, 14, 18) |
2 | Bottom side mold trimming | TRIA (2, 3, 5) |
3 | Bottom web reinforcement hoisting | TRIA (3, 4, 6) |
4 | Inner mold hoisting | TRIA (1.5, 2, 2.5) |
5 | Roof reinforcement binding | TRIA (9, 10, 13) |
6 | Roof reinforcement hoisting | TRIA (2, 3, 4) |
7 | Connect the roof reinforcement to the web reinforcement | TRIA (2, 3, 4) |
8 | End die mounting | TRIA (1.5, 2, 3) |
9 | Concrete pouring of beams | TRIA (5, 6, 7) |
10 | Concrete curing of beams | UNIF (50~56) [19] |
11 | Remove the end mold | TRIA (1, 1.5, 2) |
12 | Remove the inner mold | TRIA (2, 2.5, 3) |
13 | Tension preparation | TRIA (2, 2.5, 3) |
14 | Prestressed initial tension | TRIA (1.5, 2, 3) |
15 | Move the beams out of the seat | TRIA (1, 1.5, 2) |
Working Hour System | Waiting Time | Total Time Spent (h) |
---|---|---|
8 h/d | 87.0 | 195.6 |
10 h/d | 48.6 | 157.2 |
12 h/d | 41.2 | 149.8 |
14 h/d | 26.3 | 134.9 |
16 h/d | 17.3 | 125.9 |
18 h/d | 15 | 123.6 |
24 h/d | 0 | 108.6 |
Working Hour System | Efficiency (pcs/Day) |
---|---|
8 h/d | 0.123 |
10 h/d | 0.153 |
12 h/d | 0.160 |
14 h/d | 0.178 |
16 h/d | 0.190 |
18 h/d | 0.194 |
24 h/d | 0.221 |
Working Hour System | Waiting Time (h) | Total Time Spent (h) |
---|---|---|
8 h/d | 45.8 | 135.3 |
10 h/d | 24.1 | 113.6 |
12 h/d | 21.1 | 110.6 |
14 h/d | 18.5 | 108.0 |
16 h/d | 9.5 | 99.0 |
18 h/d | 4 | 93.5 |
24 h/d | 0 | 89.5 |
Item | Project Name | Temporal Distribution |
---|---|---|
2 | Bottom side mold trimming | TRIA (2, 3, 5) |
3 | Bottom web reinforcement hoisting | TRIA (3, 4, 6) |
4 | Inner mold hoisting | TRIA (1.5, 2, 2.5) |
6 | Roof reinforcement hoisting | TRIA (2, 3, 4) |
7 | Connect the roof reinforcement to the web reinforcement | TRIA (2, 3, 4) |
8 | End die mounting | TRIA (1.5, 2, 3) |
9 | Beam pouring | TRIA (3, 4, 5) |
10 | Maintenance | UNIF (16~20) |
11 | Remove the end mold | TRIA (1, 1.5, 2) |
12 | Remove the inner mold | TRIA (1, 1.5, 2) |
13 | Tension preparation | TRIA (1.5, 2, 3) |
14 | Initial tensioning | TRIA (1, 1, 1.5) |
15 | Move the beams out of the seat | TRIA (1, 1.5, 2) |
Working Hour System | Waiting Time (h) | Total Time Spent (h) | Efficiency of a Single Pedestal (pcs/d) |
---|---|---|---|
8 h/d | 38.0 | 87.3 | 0.275 |
10 h/d | 25.3 | 74.6 | 0.322 |
12 h/d | 19.8 | 69.1 | 0.347 |
14 h/d | 10.1 | 59.4 | 0.404 |
16 h/d | 8.4 | 57.7 | 0.416 |
18 h/d | 3.5 | 52.8 | 0.455 |
24 h/d | 0 | 49.3 | 0.487 |
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Huang, Y.; Yang, T.; Liu, B.; Xue, Y.; Li, Q. Simulation Experiment Research on the Production of Large Box Girders. Buildings 2024, 14, 3338. https://doi.org/10.3390/buildings14113338
Huang Y, Yang T, Liu B, Xue Y, Li Q. Simulation Experiment Research on the Production of Large Box Girders. Buildings. 2024; 14(11):3338. https://doi.org/10.3390/buildings14113338
Chicago/Turabian StyleHuang, Yufeng, Tongquan Yang, Bo Liu, Yang Xue, and Qingfu Li. 2024. "Simulation Experiment Research on the Production of Large Box Girders" Buildings 14, no. 11: 3338. https://doi.org/10.3390/buildings14113338
APA StyleHuang, Y., Yang, T., Liu, B., Xue, Y., & Li, Q. (2024). Simulation Experiment Research on the Production of Large Box Girders. Buildings, 14(11), 3338. https://doi.org/10.3390/buildings14113338