CN112091471A - Processing method of steel beam component structure and steel beam component structure - Google Patents
Processing method of steel beam component structure and steel beam component structure Download PDFInfo
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- CN112091471A CN112091471A CN202011247718.2A CN202011247718A CN112091471A CN 112091471 A CN112091471 A CN 112091471A CN 202011247718 A CN202011247718 A CN 202011247718A CN 112091471 A CN112091471 A CN 112091471A
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- Optics & Photonics (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses a processing method of a steel beam component structure, which comprises the following steps: the method comprises the steps of processing and manufacturing a top plate and web T-shaped unit element, processing and manufacturing a bottom plate unit element, processing and manufacturing a diaphragm unit element, assembling the top plate and web T-shaped unit element, the bottom plate unit element and the diaphragm unit element into a steel beam component body by an assembling method, and connecting two adjacent sections of the steel beam component body by splicing and welding; the invention has strict process requirements before, during and after welding, has strict storage and treatment requirements on welding materials, and adopts different welding treatment modes aiming at different welding environments, thereby ensuring that the whole welding process can be carried out orderly on one hand, and ensuring high-quality welding of steel even under severe construction environments such as low temperature, high cold or rain and snow on the other hand as far as possible, and avoiding the influence on the service performance and the service life of a steel beam component caused by the welding quality problem in the follow-up process.
Description
Technical Field
The invention relates to the technical field of processing of steel beam members, in particular to a processing method of a steel beam member, and further relates to a steel beam member structure manufactured by the processing method.
Background
The steel beam component system has the comprehensive advantages of light dead weight, factory manufacturing, quick installation, short construction period, good anti-seismic performance, quick investment recovery, less environmental pollution and the like, has unique advantages of development in three aspects of height, size and light, and is reasonably and widely applied to the field of constructional engineering and the like in the global range, particularly developed countries and regions.
In the use process of the steel beam member, assembly, lap joint and the like are needed, and the steel beam member is mostly fixed by adopting a welding mode, in the prior art, the welding quality problems such as cracks, slag inclusion, air holes and the like are easily caused due to welding environment, welding mode, welding process and the like during welding, especially the welding quality is difficult to ensure in high-cold or ice and snow construction environment, the construction period is influenced, and the service performance and the service life of the steel beam member are influenced.
Therefore, in order to avoid prolonging the construction period and not affecting the service performance and service life of the steel beam member, a method for processing a steel beam member structure with high welding quality is needed, and a steel beam member structure manufactured by the processing method is further provided.
Disclosure of Invention
The present invention is directed to a method for manufacturing a steel beam member structure and a steel beam member structure, so as to solve the problems of the background art.
In order to achieve the purpose, the invention provides a processing method of a steel beam component structure, which comprises the following steps: the method comprises the steps of processing and manufacturing a top plate and web T-shaped unit element, processing and manufacturing a bottom plate unit element, processing and manufacturing a diaphragm unit element, assembling the top plate and web T-shaped unit element, the bottom plate unit element and the diaphragm unit element into a steel beam component body by an assembling method, and connecting two adjacent sections of the steel beam component body by splicing and welding; the technological requirements of assembly welding comprise
Firstly, before welding, cleaning the surfaces of the weld areas of 40-60mm of the adjacent two sections of steel beam bodies, and polishing the areas of 30-80mm on two sides and the front and back surfaces of the weld until the metal luster appears;
secondly, welding is carried out within 24 hours after the first step is finished;
thirdly, when the ambient temperature is lower than 5 ℃, preheating by adopting a flame heating method; preheating range: measuring the temperature of the weld seam in a range of 30-50mm by using an infrared thermometer in a region of 50-80mm on both sides of the weld seam, wherein the preheating temperature is required to be 80-100 ℃;
fourthly, baking the welding rod before use, wherein the water content of the welding rod is not more than 0.1%; after the baking is qualified, storing the mixture in an oven at the temperature of 80-100 ℃, taking out the mixture when in use, placing the mixture in a heat-preserving cylinder, and taking the mixture for use at any time;
when the ambient temperature is lower than 5 ℃, the welding rod is exposed for more than 2 hours and needs to be baked again, and the baking frequency of the welding rod is not more than 3 times;
when the environmental temperature is 5-0 ℃, hammering the surface of the welding seam by using a small pointed hammer after welding and forming a plurality of hammering points on the surface;
and seventhly, when the ambient temperature is lower than 0 ℃, heat preservation is carried out on the welding seam by adopting a heat preservation measure.
And thirdly, preheating simultaneously in tandem along the direction of the welding line, wherein the distance between the preheating and the welding line is 500-800 mm.
In the seventh step, covering the welding seam area with asbestos cloth for 1-2 hours if the temperature after welding is higher than 150 ℃; if the temperature after welding is lower than 150 ℃, a flame heating method is adopted for emergency preheating to recover the temperature of the welding line area to be more than 150 ℃, and then asbestos cloth is adopted to cover the welding line area for 1-2 hours.
Seventhly, if the welding is multi-layer and multi-pass welding, after each layer of welding is finished, heat preservation is carried out by using asbestos cloth, temperature measurement is needed when the lower layer of welding is carried out, if the interlayer temperature is not lower than the preheating temperature and not higher than 200 ℃, the lower layer of welding is directly carried out, and if the interlayer temperature is lower than the preheating temperature, the welding area is heated to the preheating temperature, and then the lower layer of welding is carried out.
During heat preservation, the asbestos cloth is paved with 1500mm in the width direction of the welding line by taking the welding line as the center, and the distance from the welding point is 400-500 mm.
When gas shielded welding is adopted, the purity of the used carbon dioxide is not lower than 99.5 percent, and the water content is not more than 0.005 percent; when bottled gas is used, the pressure in the bottle must not be less than 1N/mm 2.
When in low-temperature construction, one welding seam needs to be welded at one time; if the interruption occurs, preheating the welding line by adopting a flame heating mode, wherein the preheating temperature is the same as the interlayer temperature of the welding line.
The machining and manufacturing process of the top plate and web T-shaped unit piece comprises the following steps:
a1, checking whether the materials, the external dimensions, the diagonal dimensions and the grooves of the web plate, the top plate and the longitudinal ribs of the web plate meet the requirements or not;
a2, aligning the web plates with the web plate longitudinal ribs and aligning the web plates with the top plate respectively, and welding in a ship-shaped or sub-ship-shaped welding mode by adopting a trolley;
a3, correcting the unit element formed by the A2, and performing rust removal coating after the unit element is qualified;
a4, double-splicing the single element formed by the A3, and then welding the web vertical ribs and the web in a line-to-line mode;
a5, correcting the unit piece processed by the A4 to obtain the required T-shaped unit piece of the top plate and the web;
the machining and manufacturing process of the base plate unit piece comprises the following steps:
b1, checking whether the material, the external dimension, the diagonal dimension and the groove of the bottom plate meet the requirements or not;
b2, aligning the longitudinal ribs of the bottom plate with the bottom plate and welding the longitudinal ribs and the bottom plate in a ship-shaped or sub-ship-shaped welding mode by adopting a trolley;
b3, correcting the unit pieces processed by the B2 to obtain the required bottom plate unit pieces;
the processing and manufacturing process of the diaphragm single element comprises a bottom plate transverse rib manufacturing method and a web plate vertical rib manufacturing method;
the manufacturing method of the transverse rib of the bottom plate comprises the following steps:
c1, checking whether the material, the external dimension, the diagonal dimension and the groove of the web plate and the wing plate of the transverse rib of the bottom plate meet the requirements or not;
c2, marking the wing plates of the transverse ribs of the bottom plate, and then assembling and welding the web plates and the wing plates of the transverse ribs of the bottom plate;
c3, correcting the unit piece processed by the C2 to obtain the required diaphragm unit piece;
the manufacturing method of the web vertical rib comprises the following steps:
d1, checking whether the material, the external dimension, the diagonal dimension and the groove of the web plate and the wing plate of the vertical rib of the web plate meet the requirements or not;
d2, marking the wing plates of the web vertical ribs, and assembling and welding the web and the wing plates of the web vertical ribs;
d3, correcting the D2 processed single elements to obtain the required diaphragm single elements.
The assembling method of the top plate and web T-shaped unit piece, the bottom plate unit piece and the diaphragm unit piece which are assembled into the steel beam component body comprises the following steps:
e1, arranging a ground sample line and a jig frame according to requirements, and rigidly and fixedly connecting the bottom plate unit piece and the jig frame template and aligning the bottom plate unit piece and the ground sample line;
e2, assembling, temporarily supporting and fixing the upper jig frame of the transverse rib of the bottom plate, assembling the upper jig frame of the T-shaped unit piece of the top plate and the web plate in parallel, and integrally welding and correcting;
e3, partitioning the partition plate units, and performing sectional tire removal and correction;
e4, welding shear nails, lifting lugs or other accessories, and performing sectional coating to obtain the required steel beam member body.
The invention further provides an anti-corrosion steel beam component structure which comprises at least two sections of steel beam component bodies, a first anti-corrosion film layer sprayed on the outer surface of each steel beam component body, a second anti-corrosion film layer sprayed on the inner surface of each steel beam component body, and third anti-corrosion film layers sprayed on two sides of the upper surface of a flange of each steel beam component; the steel beam component body is processed by adopting the processing method of the steel beam component structure.
Compared with the prior art, the invention has the beneficial effects that:
1. in the invention, the process requirements before, during and after welding are strict, the welding materials are strictly stored and processed, and different welding processing modes are adopted aiming at different welding environments, so that on one hand, the whole welding process can be carried out orderly, on the other hand, the high-quality welding of the steel under severe construction environments such as low temperature, high cold or rain and snow is ensured as much as possible, and the influence on the service performance and the service life of the steel beam component caused by the welding quality problem in the follow-up process is avoided.
2. In the invention, the preheating is carried out simultaneously along the direction of the welding seam in a tandem mode, and the distance between the preheating and the welding seam is 500-800mm, thus not only improving the preheating efficiency, but also avoiding the occurrence of interference.
3. In the invention, multilayer multi-pass welding is adopted, so that the weld joint structure of the butt weld joint can be improved, grains are refined, and the low-temperature impact toughness of the weld joint is improved.
4. In the invention, during low-temperature construction, one welding seam is welded as much as possible to prevent overlarge temperature gradient during heat dissipation of the welding seam.
5. In the invention, when the environmental temperature is 5-0 ℃, a small pointed hammer is needed to be adopted to hammer on the surface of the welding seam after welding and form a plurality of hammering points on the surface, thereby being beneficial to releasing the residual welding stress and avoiding stress concentration; when the ambient temperature is lower than 0 ℃, heat preservation measures are adopted to preserve heat of the welding seams, so that cold cracks in a heat affected zone due to over cooling speed are prevented.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "vertical", "upper", "lower", "horizontal", and the like indicate orientations or positional relationships only for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the referred devices or elements must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention.
In the description of the present invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly and may, for example, be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
Example 1
The embodiment provides a processing method of a steel beam component structure, which comprises the following steps: the method comprises the steps of processing and manufacturing a top plate and web T-shaped unit element, processing and manufacturing a bottom plate unit element, processing and manufacturing a diaphragm unit element, assembling the top plate and web T-shaped unit element, the bottom plate unit element and the diaphragm unit element into a steel beam component body by an assembling method, and connecting two adjacent sections of the steel beam component body by splicing and welding; the technological requirements of assembly welding comprise
Firstly, before welding, cleaning the surfaces of the weld areas of 40-60mm of the adjacent two sections of steel beam bodies, and polishing the areas of 30-80mm on two sides and the front and back surfaces of the weld until the metal luster appears;
secondly, welding is carried out within 24 hours after the first step is finished;
thirdly, when the ambient temperature is lower than 5 ℃, preheating by adopting a flame heating method; preheating range: measuring the temperature of the weld seam in a range of 30-50mm by using an infrared thermometer in a region of 50-80mm on both sides of the weld seam, wherein the preheating temperature is required to be 80-100 ℃;
fourthly, baking the welding rod before use, wherein the water content of the welding rod is not more than 0.1%; after the baking is qualified, storing the mixture in an oven at the temperature of 80-100 ℃, taking out the mixture when in use, placing the mixture in a heat-preserving cylinder, and taking the mixture for use at any time;
when the ambient temperature is lower than 5 ℃, the welding rod is exposed for more than 2 hours and needs to be baked again, and the baking frequency of the welding rod is not more than 3 times;
when the environmental temperature is 5-0 ℃, hammering the surface of the welding seam by using a small pointed hammer after welding and forming a plurality of hammering points on the surface;
and seventhly, when the ambient temperature is lower than 0 ℃, heat preservation is carried out on the welding seam by adopting a heat preservation measure.
In the embodiment, the process requirements before, during and after welding are strict, the welding materials are strictly stored and processed, and different welding processing modes are adopted for different welding environments, so that on one hand, the whole welding process can be performed orderly, on the other hand, high-quality welding of steel under severe construction environments such as low temperature, high cold or rain and snow is ensured as much as possible, and the influence on the service performance and the service life of the steel beam component caused by the welding quality problem in the follow-up process is avoided. As a preferred embodiment of the present embodiment, when the ambient temperature is 5 ℃ to 0 ℃, a small pointed hammer is required to hammer the surface of the weld joint after welding and form a plurality of hammering points on the surface, thereby facilitating the release of the welding residual stress and avoiding stress concentration; when the ambient temperature is lower than 0 ℃, heat preservation measures are adopted to preserve heat of the welding seams, so that cold cracks in a heat affected zone due to over cooling speed are prevented.
Further, in the third step, preheating is carried out simultaneously in a tandem mode along the direction of the welding line, and the distance between the preheating and the welding line is 500-800 mm; therefore, the preheating efficiency can be improved, and the interference is avoided. Meanwhile, during low-temperature construction, one welding seam needs to be welded at one time; if the interruption occurs, preheating the welding seam by adopting a flame heating mode, wherein the preheating temperature is the same as the interlayer temperature of the welding seam, so that the overlarge temperature gradient is prevented when the welding seam radiates.
On the basis of the embodiment, the butt welding seam is preferably multilayer multi-pass welding, then after each layer of welding is finished, the heat is preserved by adopting asbestos cloth, when the lower layer of welding is carried out, the temperature is required to be measured, if the interlayer temperature is not lower than the preheating temperature and is not higher than 200 ℃, the lower layer of welding is directly carried out, and if the interlayer temperature is lower than the preheating temperature, the welding area is firstly heated to the preheating temperature, and then the lower layer of welding is carried out; by adopting multilayer multi-pass welding, the weld joint structure of the butt weld joint can be improved, crystal grains are refined, and the low-temperature impact toughness of the weld joint is improved.
In the seventh step, covering the welding seam area with asbestos cloth for 1-2 hours if the temperature after welding is higher than 150 ℃; if the temperature after welding is lower than 150 ℃, a flame heating method is adopted for emergency preheating to recover the temperature of the welding line area to be more than 150 ℃, and then asbestos cloth is adopted to cover the welding line area for 1-2 hours.
As a specific implementation mode, in the heat preservation process, the asbestos cloth is paved with 1500mm along the width direction of the welding line by taking the welding line as the center, and the distance from the welding point is 400-500 mm.
Further, in the embodiment, when gas shielded welding is adopted, the purity of the used carbon dioxide is not lower than 99.5%, and the water content is not more than 0.005%; when bottled gas is used, the pressure in the bottle must not be less than 1N/mm 2.
For unqualified welding seams of a construction site, the welding seams are required to be repaired, the repairing times of the unqualified welding seams are not more than twice, and the welding seam repairing method comprises the following steps:
1. defects left when cutting off the temporary connection plates: the surface depth of the damaged steel is more than 0.1mm and less than 1mm, and the steel is ground by a grinding wheel; the depth of the repair welding exceeds 1mm, and the repair welding is carried out manually and then the grinding wheel is dressed;
2. undercut: the depth is less than 0.5mm, and the grinding wheel is adopted for smoothing; the depth is larger than 0.5mm, and the grinding wheel is dressed after manual repair welding;
3. weld or shadow cracks: removing the defects by using a carbon arc gouging, finding out reasons, providing prevention measures, preheating the repair welding to 100-150 ℃, and performing repair welding by adopting the original welding method; if the length of the welding line is less than 200mm, manual welding is adopted;
4. air holes, slag inclusion, undissolved pits and the like: the defects are cleared by a carbon arc air gouging, and the defects are repaired by manual welding at the preheating temperature of 50-100 ℃ and are smoothed after welding.
5. Automatic welding, semi-automatic welding arc starting or arc dropping pits: when welding or repair welding needs to be continuously carried out, two ends of a welding seam of the pit part are planed into slopes which are not steeper than 1:5, and then welding or repair welding is carried out.
In the embodiment, different repairing methods are adopted for different weld defects, so that the weld defects are repaired in place to the greatest extent.
The machining and manufacturing process of the top plate and web T-shaped unit piece comprises the following steps:
a1, checking whether the materials, the external dimensions, the diagonal dimensions and the grooves of the web plate, the top plate and the longitudinal ribs of the web plate meet the requirements or not;
a2, aligning the web plates with the web plate longitudinal ribs and aligning the web plates with the top plate respectively, and welding in a ship-shaped or sub-ship-shaped welding mode by adopting a trolley;
a3, correcting the unit element formed by the A2, and performing rust removal coating after the unit element is qualified;
a4, double-splicing the single element formed by the A3, and then welding the web vertical ribs and the web in a line-to-line mode;
a5, correcting the unit piece processed by the A4 to obtain the required T-shaped unit piece of the top plate and the web;
the machining and manufacturing process of the base plate unit piece comprises the following steps:
b1, checking whether the material, the external dimension, the diagonal dimension and the groove of the bottom plate meet the requirements or not;
b2, aligning the longitudinal ribs of the bottom plate with the bottom plate and welding the longitudinal ribs and the bottom plate in a ship-shaped or sub-ship-shaped welding mode by adopting a trolley;
b3, correcting the unit pieces processed by the B2 to obtain the required bottom plate unit pieces;
the processing and manufacturing process of the diaphragm single element comprises a bottom plate transverse rib manufacturing method and a web plate vertical rib manufacturing method;
the manufacturing method of the transverse rib of the bottom plate comprises the following steps:
c1, checking whether the material, the external dimension, the diagonal dimension and the groove of the web plate and the wing plate of the transverse rib of the bottom plate meet the requirements or not;
c2, marking the wing plates of the transverse ribs of the bottom plate, and then assembling and welding the web plates and the wing plates of the transverse ribs of the bottom plate;
c3, correcting the unit piece processed by the C2 to obtain the required diaphragm unit piece;
the manufacturing method of the web vertical rib comprises the following steps:
d1, checking whether the material, the external dimension, the diagonal dimension and the groove of the web plate and the wing plate of the vertical rib of the web plate meet the requirements or not;
d2, marking the wing plates of the web vertical ribs, and assembling and welding the web and the wing plates of the web vertical ribs;
d3, correcting the D2 processed single elements to obtain the required diaphragm single elements.
The assembling method of the top plate and web T-shaped unit piece, the bottom plate unit piece and the diaphragm unit piece which are assembled into the steel beam component body comprises the following steps:
e1, arranging a ground sample line and a jig frame according to requirements, and rigidly and fixedly connecting the bottom plate unit piece and the jig frame template and aligning the bottom plate unit piece and the ground sample line;
e2, assembling, temporarily supporting and fixing the upper jig frame of the transverse rib of the bottom plate, assembling the upper jig frame of the T-shaped unit piece of the top plate and the web plate in parallel, and integrally welding and correcting;
e3, partitioning the partition plate units, and performing sectional tire removal and correction;
e4, welding shear nails, lifting lugs or other accessories, and performing sectional coating to obtain the required steel beam member body.
Example 2
On the basis of the foregoing embodiments, the present embodiment further provides an anti-corrosion steel beam member structure, which includes at least two sections of steel beam member bodies, a first anti-corrosion film layer sprayed on an outer surface of the steel beam member body, a second anti-corrosion film layer sprayed on an inner surface of the steel beam member body, and third anti-corrosion film layers sprayed on two sides of an upper surface of a flange of the steel beam member; the steel beam component body is processed by the processing method of the steel beam component structure in the embodiment 1.
The first anti-corrosion film layer comprises a first cold-spray zinc film layer with the thickness of 80 microns, an epoxy micaceous iron intermediate paint with the thickness of 150 microns, and a fluorocarbon finish paint with the thickness of 35 microns, wherein the first cold-spray zinc film layer is directly sprayed on the outer surface of the steel beam component body;
the second anti-corrosion film layer comprises a second cold-sprayed zinc film layer with the thickness of 50 mu m and an epoxy thick slurry paint with the thickness of 300 mu m, wherein the second cold-sprayed zinc film layer is directly sprayed on the inner surface of the steel beam component body;
and the third corrosion prevention film layer comprises epoxy glass flake paint which is directly sprayed on two sides of the upper surface of the flange and has the thickness of 500 mu m.
In the embodiment, the bottom layer of the first anti-corrosion film layer on the outer surface of the steel beam member is a cold-sprayed zinc film layer, and a dry film of the cold-sprayed zinc contains more than 96% of pure zinc, so that good cathodic protection can be provided for steel, the steel surface can be protected for a long time even in a harsh environment, and the single-component zinc-rich coating is simple and convenient to operate; the middle layer of the first anti-corrosion film layer is epoxy micaceous iron intermediate paint, and the formed film layer has good adhesive force, wear resistance and sealing property, can protect the cold-sprayed zinc film layer of the bottom layer, and enhances the protective performance of the whole first anti-corrosion film layer; the outer layer of the first anti-corrosion film layer is fluorocarbon finish paint which has excellent weather resistance, heat resistance, low temperature resistance, chemical resistance, unique non-adhesiveness and low friction; therefore, the first anti-corrosion film layer formed by the cold spray zinc film layer, the epoxy micaceous iron intermediate paint and the fluorocarbon finish paint forms multiple protection, so that the outer surface of the steel beam member has good anti-corrosion performance even under severe environment, is not easy to corrode under the conditions of rain, snow, low temperature, ice and the like, and has good economic value; the bottom layer of the second anti-corrosion film layer on the inner surface of the steel beam member is a cold-sprayed zinc film layer, a dry film of the cold-sprayed zinc contains more than 96% of pure zinc, good cathodic protection can be provided for steel, the steel surface can be protected for a long time even in a harsh environment, and the steel surface is a single-component zinc-rich coating which is simple and convenient to operate; the outer layer of the second anticorrosive film layer on the inner surface of the steel beam member is epoxy thick-slurry paint which is high-performance anticorrosive finish paint and has a strong anticorrosive function; therefore, the second anti-corrosion film layer is formed by the cold spray zinc film layer and the epoxy thick paste paint together, so that the inner surface of the steel beam member has good anti-corrosion performance under double protection; epoxy glass flake paint with the thickness of 500 mu m is arranged on two sides of the upper surface of the flange of the steel beam member, and the epoxy glass flake paint has excellent water resistance, chemical permeation resistance, high adhesive force, mechanical strength and ideal corrosion resistance, so that the two sides of the upper surface of the flange of the steel beam member can be ensured to have good corrosion resistance even under severe environments with corrosive conditions such as concrete covered on the outer surface; in conclusion, different anticorrosion treatment processes are adopted for different surfaces, so that the whole steel beam member has good anticorrosion performance, can meet the use requirement in severe environment, and has good economic value.
The specific treatment method of each anticorrosive film layer comprises the following steps:
the first anticorrosion film layer comprises the following processing steps:
r1, pretreatment: after the outer surface of the steel beam component body is subjected to purification treatment, cleaning and drying are carried out, and surface sand blasting and rust removal as well as sand cleaning and dust removal are carried out;
r2, spraying a first anticorrosive film layer: firstly, cold spraying a first cold spraying zinc film layer with the thickness of 80 mu m, then spraying an epoxy micaceous iron intermediate paint with the thickness of 150 mu m, and finally spraying a fluorocarbon finish paint with the thickness of 35 mu m on the epoxy micaceous iron intermediate paint;
the second anticorrosion film layer comprises the following processing steps:
s1, preprocessing: after the inner surface of the steel beam component body is purified, cleaning and drying are carried out, and surface sand blasting and rust removal as well as sand cleaning and dust removal are carried out;
s2, spraying a second anticorrosive film layer: firstly, cold spraying a second cold spraying zinc film layer with the thickness of 50 mu m, and then spraying two epoxy thick paste paints with the thickness of 300 mu m;
the third corrosion prevention film layer comprises the following processing steps:
t1, pretreatment: cleaning and drying the two sides of the upper surface of the flange of the steel beam component after purifying, and performing sand blasting and rust removal on the surface and sand cleaning and dust removal;
t2, spraying a third corrosion prevention film layer: spraying a layer of epoxy glass flake paint with the thickness of 500 mu m.
The step of treating the first anticorrosive film layer further comprises the steps of R3: and after the steel beam member is conveyed to a construction site, spraying a fluorocarbon finish paint with the thickness of 35 mu m on the outer surface of the steel beam member body again.
In the embodiment, the bottom layer of the first anti-corrosion film layer on the outer surface of the steel beam member is a cold-sprayed zinc film layer, and a dry film of the cold-sprayed zinc contains more than 96% of pure zinc, so that good cathodic protection can be provided for steel, the steel surface can be protected for a long time even in a harsh environment, and the single-component zinc-rich coating is simple and convenient to operate; the middle layer of the first anti-corrosion film layer is epoxy micaceous iron intermediate paint, and the formed film layer has good adhesive force, wear resistance and sealing property, can protect the cold-sprayed zinc film layer of the bottom layer, and enhances the protective performance of the whole first anti-corrosion film layer; the outer layer of the first anti-corrosion film layer is fluorocarbon finish paint which has excellent weather resistance, heat resistance, low temperature resistance, chemical resistance, unique non-adhesiveness and low friction; therefore, the first anti-corrosion film layer formed by the cold spray zinc film layer, the epoxy micaceous iron intermediate paint and the fluorocarbon finish paint forms multiple protection, so that the outer surface of the steel beam member has good anti-corrosion performance even under severe environment, is not easy to corrode under the conditions of rain, snow, low temperature, ice and the like, and has good economic value; the bottom layer of the second anti-corrosion film layer on the inner surface of the steel beam member is a cold-sprayed zinc film layer, a dry film of the cold-sprayed zinc contains more than 96% of pure zinc, good cathodic protection can be provided for steel, the steel surface can be protected for a long time even in a harsh environment, and the steel surface is a single-component zinc-rich coating which is simple and convenient to operate; the outer layer of the second anticorrosive film layer on the inner surface of the steel beam member is epoxy thick-slurry paint which is high-performance anticorrosive finish paint and has a strong anticorrosive function; therefore, the second anti-corrosion film layer is formed by the cold spray zinc film layer and the epoxy thick paste paint together, so that the inner surface of the steel beam member has good anti-corrosion performance under double protection; epoxy glass flake paint with the thickness of 500 mu m is arranged on two sides of the upper surface of the flange of the steel beam member, and the epoxy glass flake paint has excellent water resistance, chemical permeation resistance, high adhesive force, mechanical strength and ideal corrosion resistance, so that the two sides of the upper surface of the flange of the steel beam member can be ensured to have good corrosion resistance even under severe environments with corrosive conditions such as concrete covered on the outer surface; in conclusion, different anticorrosion treatment processes are adopted for different surfaces, so that the whole steel beam member has good anticorrosion performance, can meet the use requirement in severe environment, and has good economic value.
Further, in steps R1, S1, T1, the cleaning process includes removing spatter and grinding flat, grinding flat rough welds/burrs, grinding flat surface defects, grinding R2 arcs of free edges/corners; in the steps R1, S1 and T1, the surface is cleaned by using an organic solvent if the surface has marks or oil stains, and then the surface is washed by clean water and dried. In this embodiment, polish and wash the surface to the girder steel component before the spraying, then adopt organic solvent to carry out surface cleaning to there being mark or greasy dirt, dry after the washing for corresponding surface is clean and tidy before the spraying, so that the processing of bottom rete is handled.
In the embodiment, in the steps R1, S1 and T1, steel sand or copper ore sand with the sand granularity of 0.7-1.4mm is adopted for sand blasting and rust removal, and the steel sand or the copper ore sand is cleaned and dried before use; polishing the corresponding surface to St2.5 grade by sand blasting for rust removal; the surface is derusted and polished to a required grade, so that the film layer can be better attached to the corresponding surface to form a stable bottom anti-corrosion film layer, and the required high anti-corrosion performance is realized.
Further, in the steps R2, S2 and T2, the temperature of the construction environment is 5-38 degrees, and the relative humidity is not more than 85 percent; when the construction environment temperature is-5-5 ℃, adopting a low-temperature curing product or heating treatment; finishing the spraying of the cold-sprayed zinc film layer within 4 hours after the sand blasting rust removal in the steps R1 and S1 is finished, and prolonging the time interval between the sand blasting rust removal and the cold-sprayed zinc film layer spraying when the relative humidity of the construction environment is less than 60 percent, wherein the longest time is not more than 8 hours; .
Weld joints and corners which are difficult to coat or parts which are difficult to ensure the thickness are precoated in a roller coating or brush coating mode, the precoated film layer is uniform, and the defects of missing coating, sagging, floating or other coating layers cannot be caused; in the embodiment, the special part is pre-coated, so that a complete and effective anti-corrosion film layer can be formed after the welding seams and corners of the steel beam component or the part difficult to ensure the thickness is processed, and the corrosion of a certain part of the steel beam component is effectively prevented.
As a preferred embodiment, during spraying, the distance between a spray gun and the spraying surface is kept between 25 cm and 55cm, the coating and capping are carried out uniformly, the capping is carried out 1/3 to 1/2 each time, the coating is difficult before easy, and the coating is carried out in a split manner; when in spraying, the gun nozzle is perpendicular to the corresponding surface and moves at a uniform speed, and a certain distance is kept so as to form a uniform and stable coating on the surface; the trigger of the gun must be stopped when the gun reaches the end of its travel to avoid excessive coating mist generation and excessive coating material consumption during processing.
On the basis of the above embodiment, further, before the first spraying and after each spraying, the inspection is required, and if the inspection is not qualified, the reworking is performed, and if the inspection is qualified, the next step is performed. The specific test method is as follows:
1. visual inspection
After spraying an area, observing a wet film by naked eyes, and if the wet film is wet, plump and glossy, considering that the spraying quality is good; if the wet film has poor gloss and rough feeling, the spraying is considered to be uneven, and one additional spraying is needed; in the spraying process, the coating should form a uniform continuous film without gaps, the coating leakage part should be timely sprayed, and orange peel, bubbles and other defects influencing the coating quality need to be immediately treated. In the embodiment, the visual inspection method is adopted to inspect the appearance of the coating, and the coating is uniform, fine, bright, complete and consistent in color, so that the defects of roughness, paint leakage, orange peel, color difference, pinholes, rust return, peeling, severe sagging and the like of the coating are avoided.
2. Thickness inspection
Thickness test for dry film layer:
the film thickness of 90% of the measuring points on the outer surface of the steel beam member is required to reach a specified value, 10% of the film thickness of the measuring points is allowed to be lower than the specified value, but the film thickness of each single measuring point is not lower than 90% of the specified value; the film thickness of 85% of the measuring points on the inner surface of the steel beam member is required to reach the specified value, 15% of the film thickness of the measuring points is allowed to be lower than the specified value, but the film thickness of each single measuring point is not lower than 85% of the specified value.
The dry film thickness was monitored using a magnetic thickness gauge, as specified in GB/T13452.2. When the thickness is measured, the sections are taken as a measuring unit, each measuring unit at least selects three reference surfaces, each reference surface measures 5 points, each point measures three readings in a circle with the diameter of 4cm, and the average value of the readings is the film thickness of the point. For large steel beam members, the SSPC PA2 measurement method was used.
Further, in the present embodiment, the repair of the damaged portion of the outer surface of the steel beam member body: polishing to St3.0 grade, and then sequentially coating a first cold spray zinc film layer, an epoxy micaceous iron intermediate paint and a fluorocarbon finish paint; repairing the damaged part of the inner surface of the steel beam component body: polishing to St2.5 level, and then sequentially coating a second cold spray zinc film layer and epoxy thick paste paint; and repairing the damaged part in time to ensure the integrity of the outer surface and the inner surface anticorrosive film layer of the steel beam member and avoid the local corrosion of the steel beam member.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (10)
1. A processing method of a steel beam component structure comprises the following steps: the method comprises the steps of processing and manufacturing a top plate and web T-shaped unit element, processing and manufacturing a bottom plate unit element, processing and manufacturing a diaphragm unit element, assembling the top plate and web T-shaped unit element, the bottom plate unit element and the diaphragm unit element into a steel beam component body by an assembling method, and connecting two adjacent sections of the steel beam component body by splicing and welding; the method is characterized in that: the technological requirements of assembly welding comprise
Firstly, before welding, cleaning the surfaces of the weld areas of 40-60mm of the adjacent two sections of steel beam bodies, and polishing the areas of 30-80mm on two sides and the front and back surfaces of the weld until the metal luster appears;
secondly, welding is carried out within 24 hours after the first step is finished;
thirdly, when the ambient temperature is lower than 5 ℃, preheating by adopting a flame heating method; preheating range: measuring the temperature of the weld seam in a range of 30-50mm by using an infrared thermometer in a region of 50-80mm on both sides of the weld seam, wherein the preheating temperature is required to be 80-100 ℃;
fourthly, baking the welding rod before use, wherein the water content of the welding rod is not more than 0.1%; after the baking is qualified, storing the mixture in an oven at the temperature of 80-100 ℃, taking out the mixture when in use, placing the mixture in a heat-preserving cylinder, and taking the mixture for use at any time;
when the ambient temperature is lower than 5 ℃, the welding rod is exposed for more than 2 hours and needs to be baked again, and the baking frequency of the welding rod is not more than 3 times;
when the environmental temperature is 5-0 ℃, hammering the surface of the welding seam by using a small pointed hammer after welding and forming a plurality of hammering points on the surface;
and seventhly, when the ambient temperature is lower than 0 ℃, heat preservation is carried out on the welding seam by adopting a heat preservation measure.
2. The method of processing a steel girder member structure according to claim 1, wherein: and thirdly, preheating simultaneously in tandem along the direction of the welding line, wherein the distance between the preheating and the welding line is 500-800 mm.
3. The method of processing a steel girder member structure according to claim 1, wherein: in the seventh step, covering the welding seam area with asbestos cloth for 1-2 hours if the temperature after welding is higher than 150 ℃; if the temperature after welding is lower than 150 ℃, a flame heating method is adopted for emergency preheating to recover the temperature of the welding line area to be more than 150 ℃, and then asbestos cloth is adopted to cover the welding line area for 1-2 hours.
4. The method of processing a steel girder member structure according to claim 1, wherein: seventhly, if the welding is multi-layer and multi-pass welding, after each layer of welding is finished, heat preservation is carried out by using asbestos cloth, temperature measurement is needed when the lower layer of welding is carried out, if the interlayer temperature is not lower than the preheating temperature and not higher than 200 ℃, the lower layer of welding is directly carried out, and if the interlayer temperature is lower than the preheating temperature, the welding area is heated to the preheating temperature, and then the lower layer of welding is carried out.
5. The method of processing a steel girder member structure according to claim 3, wherein: during heat preservation, the asbestos cloth is paved with 1500mm in the width direction of the welding line by taking the welding line as the center, and the distance from the welding point is 400-500 mm.
6. The method of processing a steel girder member structure according to claim 1, wherein: when gas shielded welding is adopted, the purity of the used carbon dioxide is not lower than 99.5 percent, and the water content is not more than 0.005 percent; when bottled gas is used, the pressure in the bottle must not be less than 1N/mm 2.
7. The method of processing a steel girder member structure according to claim 1, wherein: when in low-temperature construction, one welding seam needs to be welded at one time; if the interruption occurs, preheating the welding line by adopting a flame heating mode, wherein the preheating temperature is the same as the interlayer temperature of the welding line.
8. The method of processing a steel girder member structure according to claim 1, wherein:
the machining and manufacturing process of the top plate and web T-shaped unit piece comprises the following steps:
a1, checking whether the materials, the external dimensions, the diagonal dimensions and the grooves of the web plate, the top plate and the longitudinal ribs of the web plate meet the requirements or not;
a2, aligning the web plates with the web plate longitudinal ribs and aligning the web plates with the top plate respectively, and welding in a ship-shaped or sub-ship-shaped welding mode by adopting a trolley;
a3, correcting the unit element formed by the A2, and performing rust removal coating after the unit element is qualified;
a4, double-splicing the single element formed by the A3, and then welding the web vertical ribs and the web in a line-to-line mode;
a5, correcting the unit piece processed by the A4 to obtain the required T-shaped unit piece of the top plate and the web;
the machining and manufacturing process of the base plate unit piece comprises the following steps:
b1, checking whether the material, the external dimension, the diagonal dimension and the groove of the bottom plate meet the requirements or not;
b2, aligning the longitudinal ribs of the bottom plate with the bottom plate and welding the longitudinal ribs and the bottom plate in a ship-shaped or sub-ship-shaped welding mode by adopting a trolley;
b3, correcting the unit pieces processed by the B2 to obtain the required bottom plate unit pieces;
the processing and manufacturing process of the diaphragm single element comprises a bottom plate transverse rib manufacturing method and a web plate vertical rib manufacturing method;
the manufacturing method of the transverse rib of the bottom plate comprises the following steps:
c1, checking whether the material, the external dimension, the diagonal dimension and the groove of the web plate and the wing plate of the transverse rib of the bottom plate meet the requirements or not;
c2, marking the wing plates of the transverse ribs of the bottom plate, and then assembling and welding the web plates and the wing plates of the transverse ribs of the bottom plate;
c3, correcting the unit piece processed by the C2 to obtain the required diaphragm unit piece;
the manufacturing method of the web vertical rib comprises the following steps:
d1, checking whether the material, the external dimension, the diagonal dimension and the groove of the web plate and the wing plate of the vertical rib of the web plate meet the requirements or not;
d2, marking the wing plates of the web vertical ribs, and assembling and welding the web and the wing plates of the web vertical ribs;
d3, correcting the D2 processed single elements to obtain the required diaphragm single elements.
9. The method of processing a steel girder member structure according to claim 1, wherein: the assembling method of the top plate and web T-shaped unit piece, the bottom plate unit piece and the diaphragm unit piece which are assembled into the steel beam component body comprises the following steps:
e1, arranging a ground sample line and a jig frame according to requirements, and rigidly and fixedly connecting the bottom plate unit piece and the jig frame template and aligning the bottom plate unit piece and the ground sample line;
e2, assembling, temporarily supporting and fixing the upper jig frame of the transverse rib of the bottom plate, assembling the upper jig frame of the T-shaped unit piece of the top plate and the web plate in parallel, and integrally welding and correcting;
e3, partitioning the partition plate units, and performing sectional tire removal and correction;
e4, welding shear nails, lifting lugs or other accessories, and performing sectional coating to obtain the required steel beam member body.
10. An anticorrosive girder steel component structure which characterized in that: the steel beam component comprises at least two sections of steel beam component bodies, a first anti-corrosion film layer sprayed on the outer surface of each steel beam component body, a second anti-corrosion film layer sprayed on the inner surface of each steel beam component body, and third anti-corrosion film layers sprayed on two sides of the upper surface of a flange of each steel beam component;
wherein the steel beam member body is processed by the processing method of the steel beam member structure according to any one of claims 1 to 9.
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Effective date of registration: 20231218 Address after: No. 646, Zhongyi 1st Road, Yuhua District, Changsha City, Hunan Province Patentee after: CHINA RAILWAY WUJU GROUP THE FIRST ENGINEERING Co.,Ltd. Patentee after: Ningxia Jiaotou Engineering Construction Management Co.,Ltd. Address before: 410000 no.646 Zhongyi 1st Road, Yuhua District, Changsha City, Hunan Province Patentee before: CHINA RAILWAY WUJU GROUP THE FIRST ENGINEERING Co.,Ltd. |