兩種國內常見的管樁生產線設備布局方案解析
由于工程建設對管樁用量的大量需求,PHC管樁生產線也像雨后春筍般涌現,例如無為縣的劉渡、巢湖的銀屏山、蕪湖市的三山和馬鞍山的銅閘相繼建成或正在興建之中。筆者對管樁生產線進行了學習和研究,同時也考察了國內的許多廠家和生產線,并且自己也主持設計了馬鞍山的一條管樁生產線。現對管樁生產線的設計提一點自己看法,供參考。
一、管樁的結構
管樁(zhuang)是由C80混凝土、預應力鋼筋骨架以及(ji)鋼構的端頭板和樁(zhuang)套箍等幾部(bu)分(fen)組成(cheng)。
管樁混(hun)凝土所用(yong)水(shui)(shui)泥(ni)為(wei)強度等(deng)級不(bu)低于42.5MPa的硅酸(suan)(suan)(suan)鹽水(shui)(shui)泥(ni)、普通硅酸(suan)(suan)(suan)鹽水(shui)(shui)泥(ni)或礦碴(cha)硅酸(suan)(suan)(suan)鹽水(shui)(shui)泥(ni),其(qi)質量應符合GB175-2007《通用(yong)硅酸(suan)(suan)(suan)鹽水(shui)(shui)泥(ni)》的規(gui)定;其(qi)他材料有細骨料砂(sha)、粗骨料碎石、減水(shui)(shui)劑、水(shui)(shui)等(deng)。
預應(ying)力鋼(gang)筋(jin)骨架由PC鋼(gang)棒和低(di)碳鋼(gang)熱軋圓盤條螺(luo)旋筋(jin)采用滾焊機自(zi)動焊接而(er)成,PC鋼(gang)棒的質量應(ying)符(fu)合GB/T5223.3-2005《預應(ying)力混(hun)凝(ning)土用鋼(gang)棒》的規(gui)定。
鋼(gang)構的(de)端頭(tou)板性能應符合JC/T 947-2005《先(xian)張法預應力混凝土管樁用端板》的(de)規(gui)定(ding),材質應采(cai)用Q235B。
二、生產線的設計
1. 管樁生產線工(gong)藝(yi)流(liu)程
計量→攪拌→布料→預(yu)應力張拉→離(li)心成(cheng)型→蒸(zheng)汽養護(hu)→放張脫模→高壓蒸(zheng)養→成(cheng)品檢驗(yan)→成(cheng)品堆(dui)場(chang)。生產工藝流(liu)(liu)程(cheng)圖見圖1。其(qi)基本要求是工藝流(liu)(liu) 暢、簡潔、減(jian)少運輸(shu)、減(jian)少交叉作業(ye)。保(bao)證各(ge)流(liu)(liu)程(cheng)的平衡作業(ye),以防出現(xian)各(ge)道工序互相影響(xiang)的現(xian)象。
圖(tu)1 管樁生產工(gong)藝(yi)流(liu)程圖(tu)
2. 工藝設備的選擇
工(gong)藝設(she)備的(de)選型首先要根據(ju)工(gong)藝流程、各道工(gong)序的(de)平(ping)衡來(lai)確(que)定,從(cong)經濟性和合理性兩方面(mian)考(kao)慮,按每班工(gong)作10h,產(chan)(chan)量(liang)220?270條選擇(ze)設(she)備。先確(que)定混(hun)(hun)凝(ning)土(tu)(tu)的(de)產(chan)(chan)量(liang),需1.5m3混(hun)(hun)凝(ning)土(tu)(tu)攪拌機(ji)(ji)(ji)2臺(tai),產(chan)(chan)出的(de)混(hun)(hun)凝(ning)土(tu)(tu)供6臺(tai)離心機(ji)(ji)(ji)生產(chan)(chan),根據(ju)混(hun)(hun)凝(ning)土(tu)(tu)管(guan)樁的(de)預養時間和蒸養時間的(de)需求,建3m×15m×2.5m蒸養池10個(ge),其(qi)他設(she)備可選擇(ze)滾焊(han)機(ji)(ji)(ji)2臺(tai),張(zhang)拉機(ji)(ji)(ji)2臺(tai),蒸壓釜3臺(tai),鐓頭機(ji)(ji)(ji)4臺(tai),切(qie)斷機(ji)(ji)(ji)1臺(tai),混(hun)(hun)凝(ning)土(tu)(tu)布料車(che)4臺(tai),行(xing)車(che)4?5臺(tai)。
混(hun)(hun)凝(ning)土(tu)(tu)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)機(ji)(ji)(ji)有3種(zhong)。一是(shi)立軸(zhou)式強制混(hun)(hun)凝(ning)土(tu)(tu)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)機(ji)(ji)(ji),二是(shi)雙軸(zhou)臥式混(hun)(hun)凝(ning)土(tu)(tu)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)機(ji)(ji)(ji),三是(shi)立軸(zhou)行星(xing)(xing)式混(hun)(hun)凝(ning)土(tu)(tu)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)機(ji)(ji)(ji)。管樁(zhuang)混(hun)(hun)凝(ning)土(tu)(tu)介于塑性與干(gan)硬性之間,坍落度比(bi)較小,一般為(wei)2?5cm,我們選用立軸(zhou)行星(xing)(xing)式混(hun)(hun)凝(ning)土(tu)(tu)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)機(ji)(ji)(ji),該機(ji)(ji)(ji)型的優點(dian)是(shi)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)葉由多組攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)臂組成,既(ji)有公(gong)轉又有自轉,運動軌(gui)跡復雜,攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)強烈、均勻,可縮(suo)短攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)時(shi)間,拆卸維修容(rong)易(yi)。馬鞍山(shan)以生產Ф300mm?Ф500mm管樁(zhuang)為(wei)主,經比(bi)較,選用山(shan)東圓(yuan)友集團產1.5m3混(hun)(hun)凝(ning)土(tu)(tu)攪(jiao)(jiao)(jiao)(jiao)(jiao)拌(ban)機(ji)(ji)(ji)。
對于其他設備(bei),切斷機(ji)(ji)以可切Ф7 mm?Ф11mm鋼筋(jin)即(ji)可;張(zhang)拉機(ji)(ji)需根據管樁(zhuang)規(gui)格和型號來選(xuan)擇,小型管樁(zhuang)可選(xuan)100t的(de)張(zhang)拉機(ji)(ji),為(wei)(wei)了考(kao)慮(lv)生產余(yu)量,我們選(xuan)用了200t的(de)張(zhang)拉機(ji)(ji);離心(xin)機(ji)(ji)選(xuan)用Ф300mm?Ф600mm通用型;蒸養釜以長(chang)度為(wei)(wei)2?3根樁(zhuang)長(chang)再加400mm間隙(xi),高度為(wei)(wei)3.2m;滾(gun)焊機(ji)(ji)選(xuan)用Ф300mm?Ф600mm通用型;鐓(dui)頭(tou)機(ji)(ji)選(xuan)擇可鐓(dui)Ф7mm?Ф11mm的(de)鐓(dui)頭(tou)機(ji)(ji)。
3. 生產工序(xu)平衡的確定(ding)
生(sheng)(sheng)產(chan)(chan)(chan)車(che)間設(she)計的(de)(de)(de)一個中心(xin)內容就是如何確定各(ge)生(sheng)(sheng)產(chan)(chan)(chan)工(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)平衡(heng),使(shi)每道工(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)生(sheng)(sheng)產(chan)(chan)(chan)時(shi)間相等,做(zuo)到生(sheng)(sheng)產(chan)(chan)(chan)工(gong)(gong)(gong)(gong)藝流程的(de)(de)(de)各(ge)道工(gong)(gong)(gong)(gong)序(xu)(xu)進行均衡(heng)有序(xu)(xu)地(di)生(sheng)(sheng)產(chan)(chan)(chan),使(shi)產(chan)(chan)(chan)品能在各(ge)道工(gong)(gong)(gong)(gong)序(xu)(xu)中按照設(she)定的(de)(de)(de)節奏有序(xu)(xu)順暢地(di)進行。工(gong)(gong)(gong)(gong)序(xu)(xu)節奏主要(yao)由工(gong)(gong)(gong)(gong)藝設(she)備和(he)人員(yuan)來決定,管(guan)樁生(sheng)(sheng)產(chan)(chan)(chan)線的(de)(de)(de)工(gong)(gong)(gong)(gong)序(xu)(xu)平衡(heng),一般以(yi)混凝(ning)土攪拌(ban)工(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)時(shi)間為依據,按照攪拌(ban)工(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)時(shi)間來確定各(ge)道工(gong)(gong)(gong)(gong)序(xu)(xu)所(suo)需(xu)的(de)(de)(de)生(sheng)(sheng)產(chan)(chan)(chan)設(she)備和(he)數量(liang),以(yi)滿足生(sheng)(sheng)產(chan)(chan)(chan)工(gong)(gong)(gong)(gong)藝的(de)(de)(de)需(xu)求。
三、管樁生產線的布局
管樁(zhuang)生產線(xian)(xian)的布(bu)置(zhi)一(yi)(yi)(yi)(yi)般分(fen)為(wei)兩(liang)種,一(yi)(yi)(yi)(yi)是直線(xian)(xian)型(xing)布(bu)置(zhi),另(ling)一(yi)(yi)(yi)(yi)種是環(huan)型(xing)布(bu)置(zhi)。直線(xian)(xian)型(xing)將布(bu)料、合模、張拉(la)(la)、離心、蒸養、拆模、裝籠(long)筋、裝車等(deng)主要工(gong)序(xu)全部集中(zhong)在(zai)(zai)一(yi)(yi)(yi)(yi)個(ge)車間(jian)(jian)(jian)內(nei),將鋼(gang)筋切斷、鐓頭(tou)、滾焊、套(tao)箍端頭(tou)板制作等(deng)放在(zai)(zai)輔助(zhu)車間(jian)(jian)(jian)內(nei),物流方向(xiang)(xiang)為(wei)直線(xian)(xian)型(xing)來回往復。環(huan)型(xing)布(bu)置(zhi)將主要工(gong)序(xu)分(fen)為(wei)兩(liang)個(ge)車間(jian)(jian)(jian),其中(zhong)張拉(la)(la)、離心、蒸養工(gong)序(xu)放在(zai)(zai)一(yi)(yi)(yi)(yi)個(ge)車間(jian)(jian)(jian)內(nei),將布(bu)料、合模、拆模、裝籠(long)筋、裝車和輔助(zhu)工(gong)序(xu)鋼(gang)筋切斷、鐓頭(tou)、滾焊和套(tao)箍板制作等(deng)放在(zai)(zai)另(ling)一(yi)(yi)(yi)(yi)車間(jian)(jian)(jian)內(nei),物流方向(xiang)(xiang)為(wei)環(huan)型(xing)循環(huan)。
無為(wei)縣劉渡(du)的(de)(de)(de)(de)生產(chan)(chan)(chan)工(gong)(gong)(gong)藝為(wei)環(huan)型(xing)(xing)平面(mian)布置,巢湖(hu)銀(yin)屏(ping)山的(de)(de)(de)(de)生產(chan)(chan)(chan)工(gong)(gong)(gong)藝為(wei)直(zhi)線(xian)型(xing)(xing)布置。這兩(liang)種布置各(ge)有(you)(you)特點(dian),直(zhi)線(xian)型(xing)(xing)布置的(de)(de)(de)(de)優點(dian)是(shi)布局緊湊,占地少(shao),投(tou)資(zi)小。缺(que)點(dian)是(shi)多(duo)臺吊車(che)(che)(che)在一條軌道(dao)上,主(zhu)要(yao)(yao)工(gong)(gong)(gong)序(xu)過于(yu)(yu)集(ji)中,各(ge)道(dao)工(gong)(gong)(gong)序(xu)的(de)(de)(de)(de)步距節奏(zou)要(yao)(yao)相(xiang)互(hu)(hu)銜接,緊密配(pei)合(he),行車(che)(che)(che)的(de)(de)(de)(de)接力地點(dian)和時(shi)(shi)(shi)間一定(ding)要(yao)(yao)相(xiang)互(hu)(hu)吻合(he),否則有(you)(you)一個(ge)(ge)節點(dian)出現問題或(huo)延(yan)誤,就(jiu)會影響到全(quan)廠的(de)(de)(de)(de)生產(chan)(chan)(chan),因而對管(guan)理要(yao)(yao)求嚴(yan)格,工(gong)(gong)(gong)人(ren)素(su)質要(yao)(yao)高(gao)。另外,由于(yu)(yu)行車(che)(che)(che)在廠房內(nei)頻繁往(wang)復,工(gong)(gong)(gong)人(ren)須多(duo)次避讓(rang)(rang),生產(chan)(chan)(chan)工(gong)(gong)(gong)人(ren)操作必然(ran)會受到一定(ding)的(de)(de)(de)(de)影響,安全(quan)性較差。環(huan)型(xing)(xing)布置的(de)(de)(de)(de)優點(dian)是(shi)吊車(che)(che)(che)無須往(wang)返都吊貨,物(wu)流方向是(shi)向一個(ge)(ge)方向進行循環(huan),各(ge)工(gong)(gong)(gong)序(xu)間的(de)(de)(de)(de)步距節奏(zou)要(yao)(yao)求沒(mei)有(you)(you)直(zhi)線(xian)型(xing)(xing)那樣(yang)嚴(yan)格,各(ge)自工(gong)(gong)(gong)序(xu)可有(you)(you)一定(ding)的(de)(de)(de)(de)可支配(pei)的(de)(de)(de)(de)時(shi)(shi)(shi)間,各(ge)工(gong)(gong)(gong)序(xu)間的(de)(de)(de)(de)相(xiang)互(hu)(hu)干擾減少(shao),廠房的(de)(de)(de)(de)空間大,工(gong)(gong)(gong)人(ren)避讓(rang)(rang)吊車(che)(che)(che)的(de)(de)(de)(de)時(shi)(shi)(shi)間大為(wei)減少(shao),生產(chan)(chan)(chan)安全(quan)性明(ming)顯好于(yu)(yu)直(zhi)線(xian)型(xing)(xing)布置,生產(chan)(chan)(chan)管(guan)理要(yao)(yao)比直(zhi)線(xian)型(xing)(xing)容易,機械(xie)化程度高(gao)。其(qi)缺(que)點(dian)是(shi)廠房面(mian)積大,增加了過渡(du)車(che)(che)(che)和轉運工(gong)(gong)(gong)序(xu),投(tou)資(zi)和生產(chan)(chan)(chan)成(cheng)本(ben)要(yao)(yao)高(gao)于(yu)(yu)直(zhi)線(xian)型(xing)(xing)布置。綜合(he)考慮,筆者傾向于(yu)(yu)環(huan)型(xing)(xing)的(de)(de)(de)(de)生產(chan)(chan)(chan)布局。兩(liang)種布置形式如(ru)圖(tu)2和圖(tu)3所示。
圖2 直(zhi)線型(xing)布置兩條(tiao)生(sheng)產線
圖3 環型布置(zhi)一條生產線
四、廠房設計要求
考慮到生(sheng)產安全(quan)、物流(liu)順暢(chang)和(he)施工操作(zuo)方便,車間(jian)(jian)的跨度可(ke)按(an)單節(jie)樁(zhuang)的最長(chang)樁(zhuang)長(chang)再加5m或(huo)7m進行設(she)計(ji)。同時也可(ke)按(an)兩(liang)節(jie)樁(zhuang)長(chang)再加 3m或(huo)5m進行設(she)計(ji)。行車的軌頂標高一(yi)般為7.5m左右。行車選雙勾型(xing),每(mei)(mei)個7.5t,廠(chang)房的間(jian)(jian)數以能滿足上述生(sheng)產工藝要(yao)(yao)求即可(ke)。管(guan)樁(zhuang)的堆(dui)放場(chang)地既可(ke)選用門式(shi)(shi)吊車,也可(ke)用橋式(shi)(shi)行車。每(mei)(mei)個離(li)心機之間(jian)(jian)要(yao)(yao)設(she)一(yi)道2m高安全(quan)防護(hu)墻。廠(chang)房頂要(yao)(yao)考慮采(cai)光的問(wen)題,每(mei)(mei) 隔一(yi)個房間(jian)(jian)要(yao)(yao)設(she)置一(yi)采(cai)光帶,廠(chang)房在蒸養池頂處要(yao)(yao)設(she)一(yi)氣(qi)樓(lou)或(huo)排氣(qi)通(tong)風孔。砂石(shi)料場(chang)要(yao)(yao)能存放3d的堆(dui)料。
五、結語
PHC管樁(zhuang)生產車間的(de)設計經(jing)過多年來的(de)探索, 特別是近幾年的(de)發展,現已日趨成(cheng)熟,兩種布局(ju)方案各(ge)有特點。各(ge)企業(ye)可(ke)根據各(ge)自(zi)(zi)的(de)管理水平、人員素質、資源配(pei)備(bei)、地(di)形地(di)貌(mao)等實際情況,在管樁(zhuang)流水作(zuo)業(ye)順暢的(de)前提下,確定各(ge)自(zi)(zi)的(de)布局(ju)設計,選擇最適合自(zi)(zi)身特點的(de)工藝裝備(bei),以尋(xun)求最佳的(de)性(xing)價比和最大的(de)經(jing)濟效益。