預(yù)應(yīng)力鋼束張拉作業(yè)指導(dǎo)書

中鐵十三局集團(tuán)有限公司合福鐵路安徽段站前二標(biāo)施工過程限制標(biāo)準(zhǔn)化管理手冊(cè)編號(hào)：ZT13J-SGZD-HD-XX預(yù)應(yīng)力鋼束張拉作業(yè)指導(dǎo)書編制：審核：批準(zhǔn)：201年月日發(fā)布201年月日實(shí)施中鐵十三局集團(tuán)有限公司第六工程公司目錄1目的··············································································22編制依據(jù)············································································23適用范圍············································································24作業(yè)打算············································································24.1技術(shù)打算··········································································24.2材料、設(shè)備打算·····································································25.勞動(dòng)組織···········································································25.1勞動(dòng)力組織方式····································································25.2施工人員結(jié)合既定施工方案、機(jī)械、工期要求進(jìn)行合理配置································26材料要求···········································································26.1預(yù)應(yīng)力鋼絞線·····································································36.2錨具、夾具········································································37設(shè)備機(jī)具配置······································································38.張拉程序與工藝流程································································49.施工要求·········································································49.1技術(shù)要求·········································································49.2鋼絞線下料、穿束···································································49.3錨具及千斤頂安裝··································································49.4張拉··············································································59.5伸長(zhǎng)量的計(jì)算和量測(cè)································································510.預(yù)應(yīng)力施工質(zhì)量限制及檢驗(yàn)··························································610.1質(zhì)量限制·········································································610.2質(zhì)量檢驗(yàn)·········································································611.平安及環(huán)保要求····································································7預(yù)應(yīng)力鋼束張拉作業(yè)指導(dǎo)書1目的：新建合福鐵路(安徽段)銅陵長(zhǎng)江北引橋（40+56+40）m是施工中重點(diǎn)限制部位，為了確保懸臂澆筑連續(xù)梁張拉的施工質(zhì)量，特編制預(yù)應(yīng)力鋼束張拉作業(yè)指導(dǎo)書，用以指導(dǎo)此類工程施工。2編制依據(jù)：《鐵路預(yù)應(yīng)力混凝土連續(xù)梁懸臂澆注施工技術(shù)指南》TZ324-2010《高速鐵路橋涵工程施工質(zhì)量驗(yàn)收標(biāo)準(zhǔn)》TB10752-2010/J1148-2011《鐵路混凝土工程施工技術(shù)指南》鐵建設(shè)［2010］241號(hào)《高速鐵路橋涵工程施工技術(shù)指南》鐵建設(shè)［2010］241號(hào)3.適用范圍新建合福鐵路(安徽段)銅陵長(zhǎng)江北引橋（40+56+40）m懸臂澆筑連續(xù)梁張拉施工。4.作業(yè)打算4.1技術(shù)打算張拉人員仔細(xì)熟識(shí)圖紙規(guī)定的施工方法、張拉依次、張拉時(shí)間、張拉應(yīng)力及張拉伸長(zhǎng)量；熟識(shí)規(guī)范規(guī)定的張拉要求，及質(zhì)量標(biāo)準(zhǔn)，計(jì)算鋼絞線實(shí)際下料長(zhǎng)度、施工時(shí)與設(shè)計(jì)張拉力對(duì)應(yīng)的張拉油表值、鋼絞線各張拉階段伸長(zhǎng)值。4.2材料、設(shè)備打算4.2.1依據(jù)圖紙?jiān)O(shè)計(jì)，運(yùn)用的鋼絞線為1×7-15.2-1860-GB鋼絞線，鋼絞線運(yùn)用前由試驗(yàn)室對(duì)每批鋼絞線進(jìn)行檢驗(yàn)，檢驗(yàn)合格后才能運(yùn)用。4.2.2錨具運(yùn)用前由試驗(yàn)室進(jìn)行外觀、硬度、錨固性能及工藝性能的抽樣檢驗(yàn)，檢驗(yàn)合格的錨具才能運(yùn)用。4.2.3張拉千斤頂?shù)念~定張拉噸位為張拉力的1.5倍，張拉千斤頂在運(yùn)用前必需經(jīng)過校正，校正系數(shù)不大于1.05，校正有效期為1個(gè)月，且張拉次數(shù)不得超過300次，千斤頂拆修或更換配件應(yīng)重新校正。壓力表的表面最大讀數(shù)為張拉力的1.5倍，0.4級(jí)校正有效期為1個(gè)月。且壓力表應(yīng)與張拉千斤頂配套運(yùn)用。5.勞動(dòng)組織5.1勞動(dòng)力組織方式：采納架子隊(duì)組織模式。5.2施工人員應(yīng)結(jié)合施工方案、工期要求、機(jī)械配置等合理支配。張拉油表限制人員4人，限制張拉力及油表讀數(shù)。伸長(zhǎng)量測(cè)量人員4人。張拉工班長(zhǎng)1人，負(fù)責(zé)張拉速度等整個(gè)協(xié)調(diào)工作。電工1人。6.材料要求6.1預(yù)應(yīng)力鋼絞線依據(jù)圖紙?jiān)O(shè)計(jì)，運(yùn)用的鋼絞線為1×7-15.2-1860-GB鋼絞線，豎向采納Ф25PSB785精軋螺紋鋼，精軋螺紋鋼和鋼絞線運(yùn)用前由試驗(yàn)室對(duì)每批鋼絞線、精軋螺紋鋼進(jìn)行檢驗(yàn)，檢驗(yàn)合格后才能運(yùn)用。6.2錨具、夾具錨具運(yùn)用前由試驗(yàn)室進(jìn)行外觀、硬度、錨固性能及工藝性能的抽樣檢驗(yàn)，檢驗(yàn)合格的錨具才能運(yùn)用。7.設(shè)備機(jī)具配置張拉千斤頂和張拉油泵采納柳州OVM產(chǎn)品，張拉工作前提前標(biāo)定，詳細(xì)數(shù)量見下表：預(yù)應(yīng)力施工主要機(jī)械設(shè)備配備表序號(hào)設(shè)備名稱型號(hào)數(shù)量1油泵ZB4-50042千斤頂YCW400B43千斤頂YCW60B24千斤頂YDC240QX25卷揚(yáng)機(jī)5T26倒鏈1T48.張拉程序與工藝流程張拉程序?yàn)椋?→0.10σk（作伸長(zhǎng)量標(biāo)記）→0.2σk（作伸長(zhǎng)量標(biāo)記）→σk（靜停5分鐘）→補(bǔ)拉σk（測(cè)伸長(zhǎng)量）→錨固。（σk為張拉時(shí)的限制應(yīng)力,包括預(yù)應(yīng)力損失在內(nèi)，其值依據(jù)設(shè)計(jì)圖紙要求而定，初應(yīng)力取σk的10%。）回油自鎖錨固，測(cè)總回縮量，數(shù)據(jù)復(fù)核回油自鎖錨固，測(cè)總回縮量，數(shù)據(jù)復(fù)核補(bǔ)油至σk，測(cè)伸長(zhǎng)值，校核伸長(zhǎng)值σk（持荷5min）0.10σk/0.2σk作伸長(zhǎng)值標(biāo)記起先張拉安裝千斤頂錨具安裝穿束管道清理施工打算預(yù)應(yīng)力張拉工藝流程圖9.施工要求9.1.技術(shù)要求預(yù)應(yīng)力施工是連續(xù)梁工程中最為關(guān)鍵的工序，其施工質(zhì)量的好壞將干脆影響連續(xù)梁的有效預(yù)應(yīng)力值及最終質(zhì)量。每梁段施工必需在混凝土強(qiáng)度達(dá)到設(shè)計(jì)值95%以上、彈性模量達(dá)設(shè)計(jì)值100%、齡期不少于5d及規(guī)范要求后進(jìn)行。連續(xù)梁帶模預(yù)張拉時(shí)，內(nèi)模板應(yīng)松開，不應(yīng)對(duì)梁體壓縮造成阻礙。9.2鋼絞線下料、穿束鋼絞線進(jìn)場(chǎng)并檢驗(yàn)合格后，進(jìn)行鋼絞線下料，依據(jù)圖紙說明，鋼絞線下料長(zhǎng)度=工作長(zhǎng)度+1.56穿束前，先用空壓機(jī)吹凈孔內(nèi)雜物，并將錨墊板口內(nèi)的混凝土清除干凈，下好料的鋼絞線兩端用膠布纏牢，整體穿束。穿好的鋼絞線應(yīng)疏整，順直，不得纏在一起。9.3錨具及千斤頂安裝（1）錨具安裝前先清洗干凈，然后再安裝。先裝工作錨和工作夾片，安裝時(shí)留意工作錨在錨墊板限位槽內(nèi)，工作夾片用套管打入錨孔，外露端應(yīng)平齊，否則取下重新安裝。工作錨和工作夾片安裝好后，再安裝錨環(huán)，錨環(huán)應(yīng)緊扣工作錨。（2）張拉限位器安裝時(shí)與工作錨對(duì)正安裝。（3）千斤頂安裝時(shí)需留意千斤頂油路方向，進(jìn)油、回油油路不得裝反。（4）工具錨安裝時(shí)應(yīng)與千斤頂緊扣，工具夾片安裝前應(yīng)纏裹塑料布，并抹少量黃油，以便于張拉完成后卸頂。9.4張拉（1）依據(jù)圖紙?jiān)O(shè)計(jì)要求，本工程張拉要求砼強(qiáng)度達(dá)到設(shè)計(jì)強(qiáng)度達(dá)到設(shè)計(jì)值95%以上及彈性模量達(dá)到設(shè)計(jì)值100%，且齡期不少于5天時(shí)進(jìn)行張拉。（2）張拉前，先檢查千斤頂和錨具是否安裝好，千斤頂進(jìn)、回油油路是否正確，確認(rèn)無誤后方可進(jìn)行張拉。（3）張拉先縱向再豎向精軋螺紋鋼，最終張拉橫向。張拉時(shí)，縱向采納兩端張拉，兩側(cè)對(duì)稱張拉，由外側(cè)向內(nèi)側(cè)，先長(zhǎng)后短張拉依次。豎向和橫向均采納單端張拉。每加5MPa相互通報(bào)一次，便于調(diào)整兩端張拉速度，保持兩端一樣，張拉達(dá)到100%并測(cè)量完伸長(zhǎng)量后，計(jì)算實(shí)際伸長(zhǎng)量，并與設(shè)計(jì)伸長(zhǎng)量進(jìn)行比較，當(dāng)誤差大于6%時(shí)，應(yīng)暫停張拉，查明緣由并實(shí)行調(diào)整措施后再進(jìn)行張拉。（4）張拉至限制應(yīng)力后，持荷5min，錨固；若油壓稍有下降，須補(bǔ)油到設(shè)計(jì)噸位的油壓值，然后再卸載，卸載時(shí)應(yīng)兩端同時(shí)進(jìn)行，并限制卸載速度，卸載速度不能太快。張拉時(shí)分級(jí)加載，依據(jù)10%σk→20%σk→100%σk→補(bǔ)油至100%σk對(duì)應(yīng)的張拉力分別量測(cè)伸長(zhǎng)值。張拉限制采納張拉應(yīng)力和伸長(zhǎng)值雙控，以張拉應(yīng)力限制為主，以伸長(zhǎng)值進(jìn)行校核，當(dāng)實(shí)際伸長(zhǎng)值與理論伸長(zhǎng)值差超過6％時(shí)，應(yīng)停止張拉，等查明緣由并實(shí)行措施后再進(jìn)行施工。9.5伸長(zhǎng)量的計(jì)算和量測(cè)（1）預(yù)應(yīng)力理論伸長(zhǎng)值的計(jì)算后張法預(yù)應(yīng)力筋理論伸長(zhǎng)值及預(yù)應(yīng)力筋平均張拉力的計(jì)算公式如下：(1)(2)式中：----預(yù)應(yīng)力筋理論伸長(zhǎng)值(mm)----預(yù)應(yīng)力筋的長(zhǎng)度(mm)----預(yù)應(yīng)力筋的平均張拉力(N)----從張拉端至計(jì)算截面孔道長(zhǎng)度(m)----預(yù)應(yīng)力筋截面面積(mm2)----預(yù)應(yīng)力筋的彈性模量(Mpa)----預(yù)應(yīng)力筋張拉端的張拉力(N)----從張拉端至計(jì)算截面曲線孔道部分切線的夾角之和(rad)----孔道每米局部偏差對(duì)磨擦的影響系數(shù)，取0.00782----預(yù)應(yīng)力筋與孔道壁的磨擦系數(shù)0.23。（2）實(shí)際伸長(zhǎng)量的量測(cè)及計(jì)算方法預(yù)應(yīng)力筋張拉前，應(yīng)先調(diào)整到初應(yīng)力σ0（一般可取限制應(yīng)力的10%～20%），伸長(zhǎng)量應(yīng)從初應(yīng)力時(shí)起先量測(cè)。實(shí)際伸長(zhǎng)值除張拉時(shí)量測(cè)的伸長(zhǎng)值外，還應(yīng)加上初應(yīng)力時(shí)的推算伸長(zhǎng)量，對(duì)于后張法混凝土結(jié)構(gòu)在張拉過程中產(chǎn)生的彈性壓縮量一般可省略。實(shí)際伸長(zhǎng)值的量測(cè)采納量測(cè)千斤頂油缸行程數(shù)值的方法。在初始應(yīng)力下，量測(cè)油缸外露長(zhǎng)度，在相應(yīng)分級(jí)的荷載下量測(cè)相應(yīng)油缸外露長(zhǎng)度。實(shí)際伸長(zhǎng)值△L的計(jì)算公式如下：△L＝B+C-2AA—0～10%σk應(yīng)力下的千斤頂?shù)膶?shí)際引伸量B—20%σk應(yīng)力下的千斤頂?shù)膶?shí)際引伸量C—20%σk～100%σk應(yīng)力下的千斤頂?shù)膶?shí)際引伸量10.預(yù)應(yīng)力施工質(zhì)量限制及檢驗(yàn)10.1質(zhì)量限制10.110.1.2張拉時(shí)，預(yù)應(yīng)力筋伸長(zhǎng)值與設(shè)計(jì)伸長(zhǎng)值誤差在10.1.3依據(jù)圖紙?jiān)O(shè)計(jì)要求確定張拉依次，10.110.1《鐵路預(yù)應(yīng)力混凝土連續(xù)梁懸臂澆注施工技術(shù)指南》TZ324-2010《高速鐵路橋涵工程施工質(zhì)量驗(yàn)收標(biāo)準(zhǔn)》TB10752-2010/J1148-2011《鐵路混凝土工程施工技術(shù)指南》鐵建設(shè)［2010］241號(hào)《高速鐵路橋涵工程施工技術(shù)指南》鐵建設(shè)［2010］241號(hào)10.2質(zhì)量檢驗(yàn)10.2.110.2.210.2.3預(yù)應(yīng)力筋用錨具、夾具和連接器進(jìn)場(chǎng)時(shí)，必需對(duì)其質(zhì)量指標(biāo)進(jìn)行全面檢查并按批進(jìn)行外觀及外形尺寸、硬度、靜載錨固系數(shù)性能試驗(yàn)，其質(zhì)量必需符合設(shè)計(jì)要求和相關(guān)標(biāo)準(zhǔn)的規(guī)定。每50