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关注丨工厂预制装配式混凝土检查井的生产工艺方法分析
1、浇注成型或加辅助振动的浇注成型工艺
1, pouring molding process with casting or adding auxiliary vibration
浇注成型工艺的优点为成型工艺简单、产品形状规格大小可按模具任意成型、小批量生产灵活、产品外观光滑。
The advantages of the casting process are the simple molding process, the shape and size of the product according to the mold, the small batch production and the smooth appearance of the product.
但相对立即脱模的高频振动成型工艺方式，缺点：为规模生产时模具投入大、产能小、工人劳动强度大，原辅材料、人工及其它生产成本高。
However, the relative instant demolding mode of high-frequency vibration molding has disadvantages: large investment in mold production, low productivity, heavy labor intensity, high cost of raw materials, labor and other production.
混凝土检查井型号规格繁多，同时每套检查井由不同的部件组成。以输水检查井为例，一套完整的预制装配式混凝土检查井由井室(检查井主体，接排水管的受水部分）、井室顶板（井室与井筒间的过渡及收口）、
The concrete inspection well has a wide range of specifications, and each set of inspection wells is made up of different components. In order to check the water wells as an example, a complete set of prefabricated concrete inspection well comprises a well chamber (manhole body connected with a drain pipe by water), the well chamber roof (transition and closing well between the chamber and the shaft),
井筒（控制检查井高度及竖向通道，一般不过水）、收口板或收口圈（检查井与井盖间收口）、调节圈（微调检查井高度）等组成（如左←图）《预制混凝土检查井》行业标准（JC/T2241-2014）中光井室平面尺寸规格品种就有21种之多，每种规格品种配上2-3种高度，设计部门有50多种井室的选择余地。
The shaft (control inspection wells height and vertical channel, but the general water), closing plate or closing ring (manhole and manhole cover between the adjusting ring (closing), fine-tuning inspection wells height) etc. (such as the left figure) "precast concrete manhole" industry standard (JC/T2241-2014) in the light chamber plane size specifications there are more than 21 kinds, each kind of specifications with 2-3 height, the choice design department has more than 50 kinds of wells room.
浇注成型采用塑性混凝土，一般检查井井室成型多为带底一体、2—4个接管开孔，达到脱模强度的养护时间较普通排水管更长，采用蒸汽养护约5—6小时，如果每班生产1520个单规格井室，相比振动成型立即脱模（自然养护）模具用量为,（9~13套模具）：（1套模具+15~20个底托）。浇注成型工艺的模具费用是一笔巨大的支出，此情况较排水管生产悬辊工艺同芯模振动工艺所用模具数量及总体费用相比更严重。
The plastic concrete casting, general inspection wells room for molding with bottom one, 2 - 4 nozzle openings, curing time to demoulding strength than common drain pipe of the steam curing longer, about 5 - 6 hours, if every 1520 single class production specifications wells room, compared to the vibration molding immediately release (natural maintenance dosage (9~13) mold, mold (mold): 1 sets of +15~20 base). The cost of mold for casting process is a huge expense, which is more serious than the number and total cost of the same process.
由于浇注成型工艺生产成本高、达标产能模具用量及费用巨大等原因，一般不用该工艺方式生产常规的批量预制混凝土检查井。
Due to the high cost of casting process, reaching the standard capacity, the large amount of mold and the huge cost, the conventional batch precast concrete inspection well is usually not used.
2、 离心或悬辊成型工艺
2, centrifugal or hanging roll forming process
如筒身与底板间采用胶圈、柔性企口，加以筒、底间预埋张紧连接，产品成本增加（如：右图→）。
For example, the rubber ring and the flexible mouth are used between the barrel and the bottom plate, and the product cost is increased (for example, right map, for example).
排水管生产企业利用原有模具，成型检查井的井筒部分，是一种经济有效的方法。但井室采用二次成型拼装会影响产品质量，井室带孔，离心或悬辊成型时转速不到位或跳模，成品不密实且易发安全事故；如筒身与底板间灌入细石混凝土或砂浆，则由于二者界面收缩不一，产生裂缝；（如：左图←）
It is an economical and effective method to make use of the original mould for the production enterprise of the drainage pipe to form the well bore of the well. But the well chamber two molding assembly will affect the quality of products, the well chamber with a hole, or the centrifugal roller suspension process when the speed is not in place or jump mode, products are not dense and prone to accidents; such as the cylinder body and the bottom plate with fine stone concrete or mortar, because the two shrinkage in a production students (such as: left - crack;)
3、芯模振动成型工艺
3. Vibration molding process of core mold
芯模振动成型工艺采用干法生产，芯模高频整体振动使混凝土液化密实，同时使水泥有一定的活化以提高混凝土强度，混凝土密实度很高，可以立即脱模，大量减少了成型模具数量及总体费用，与湿法工艺相比，可减少原材料的成本和降低人工费用等。
Dry production adopts core mould vibration molding process, the vibration of the whole core frequency to make concrete and cement liquefaction and densification, have certain activation to improve the strength of concrete, concrete density is very high, can immediately release, reduce the number of mold quantity and total cost, compared with the wet process, can reduce the cost of raw materials and reduce labor cost etc..
介绍一种典型的芯模振动生产检查井井室工艺步骤：1.模具在坑内就位；2.内外模间放置排水管孔预埋件、内模顶部放置混凝土托板；3.混凝土布料、振动成型；4. 混凝土超过托板并达到井室底厚度时，碾压；5.放置井室底板并与内模顶部的托板及外模连接；6.成品及外模（含底板及混凝土托板）提出工作坑；7.吊入养护位置，下置养护支撑，脱外模及井室底板；8.养护；9.翻转并脱去混凝土托板及排水管孔预埋件；10.补井室底板与混凝土托板间工作孔；11.至成品堆场。
Introduce a typical core mould vibration production inspection well chamber process steps: 1. die in the pit in place; 2. and die placement of drainage pipe hole is arranged on the top of concrete embedded parts, mold plate; 3. concrete material, concrete plate more than 4. vibration molding; and reach the well chamber bottom thickness, rolling 5. place; well chamber floor and plate and the outer mold and the internal mold at the top of the 6. connection; finished and external mold (including the floor and concrete plate) this pit; 7. into the maintenance position, the maintenance support, and external mold and the well chamber floor; 8. maintenance; 9. flip and stripped off the concrete plate and drainage pipe 10. fill hole hole embedded; work well with concrete floor plate; 11. to finished products yard.
芯模振动生产检查井井室的工艺缺陷：
The process defects of the core mold vibration production check well chamber.
由于芯模振动成型原理方式为激振力横向传递、沿法线方向激振力衰减，在生产井室时底部朝上，井室底部成型须辅以较大的碾压力，井室底部密实度不够；
Because the core mode vibration forming principle is the lateral transfer of exciting force and the attenuation of the exciting force along normal direction, the bottom of the production chamber is upward. The bottom of the well chamber must be reinforced with larger grinding pressure, and the bottom of the well chamber is not dense enough.
养护时井室底部朝上，整体重心偏上，结构不稳，养护支撑高度不易控制，会造成井室底部顶起或轻微坍塌，产生底部裂纹；一般大口径的带底整体井室不用此工艺成型；
During the maintenance, the bottom of the well chamber is upward, the overall center of gravity is upward, the structure is unstable, and the supporting height of maintenance is not easy to control. It will cause the bottom of the well chamber to rise or collapse slightly, resulting in bottom cracks.
为达到立即脱模养护，工艺步骤过多，养护支撑、混凝土托板等模具组件用量也较多；
In order to achieve immediate demoulding maintenance, the process steps are too much, and the amount of mold components such as maintenance support and concrete braces are also more.
养护后的补孔（井室底板与混凝土托板间工作孔）费工费料（一般用掺入树脂的水泥净浆调配）。
Fill the hole after curing (floor and concrete plate between the working hole room) Liu Fei Fei (cement paste mixed with resin by blending).
为减少养护支撑、混凝土托板等模具组件用量过多的问题，国外早期的方法是在内模顶上放置一块塑胶或与混凝土连接性能稍好点的石棉板，使成型后利用井室部分壁厚支撑此板及板上的井室底部混凝土重量，使之不塌陷。
In order to reduce the maintenance support, concrete supportingplate and mould components of excessive amount of problems, early method of foreign is on top of a plastic mold placed or attached to the concrete performance slightly better asbestos point, which is formed by the well chamber wall thickness supporting the plate and plate on the bottom of the well chamber concrete weight. That does not collapse.
此方法会一定程度破坏井室整体结构，板材与混凝土间人为建立诱导缝；配合此脱模养护方法，需井室壁厚尺寸加大，混凝土密实度需充分保证以防止下沉。（如上图 ↑）
This method will destroy the overall structure of the well chamber to some extent, and establish artificial joints between the plank and concrete. If the method is used for the demoulding maintenance, the thickness of the well chamber should be increased, and the density of the concrete must be fully guaranteed to prevent subsidence. (pictured above arrow)
跟据上述情况，芯模振动成型工艺适合生产圆形中小口径井室和各规格井筒，具有生产效率高、产品质量好以及干法生产的其它优势。
According to the above situation, the core mold vibration forming process is suitable for producing circular small and medium-sized well chambers and various specifications of wellbore, and has other advantages such as high production efficiency, good product quality and dry production.
1, pouring molding process with casting or adding auxiliary vibration
浇注成型工艺的优点为成型工艺简单、产品形状规格大小可按模具任意成型、小批量生产灵活、产品外观光滑。
The advantages of the casting process are the simple molding process, the shape and size of the product according to the mold, the small batch production and the smooth appearance of the product.
但相对立即脱模的高频振动成型工艺方式，缺点：为规模生产时模具投入大、产能小、工人劳动强度大，原辅材料、人工及其它生产成本高。
However, the relative instant demolding mode of high-frequency vibration molding has disadvantages: large investment in mold production, low productivity, heavy labor intensity, high cost of raw materials, labor and other production.
混凝土检查井型号规格繁多，同时每套检查井由不同的部件组成。以输水检查井为例，一套完整的预制装配式混凝土检查井由井室(检查井主体，接排水管的受水部分）、井室顶板（井室与井筒间的过渡及收口）、
The concrete inspection well has a wide range of specifications, and each set of inspection wells is made up of different components. In order to check the water wells as an example, a complete set of prefabricated concrete inspection well comprises a well chamber (manhole body connected with a drain pipe by water), the well chamber roof (transition and closing well between the chamber and the shaft),
井筒（控制检查井高度及竖向通道，一般不过水）、收口板或收口圈（检查井与井盖间收口）、调节圈（微调检查井高度）等组成（如左←图）《预制混凝土检查井》行业标准（JC/T2241-2014）中光井室平面尺寸规格品种就有21种之多，每种规格品种配上2-3种高度，设计部门有50多种井室的选择余地。
The shaft (control inspection wells height and vertical channel, but the general water), closing plate or closing ring (manhole and manhole cover between the adjusting ring (closing), fine-tuning inspection wells height) etc. (such as the left figure) "precast concrete manhole" industry standard (JC/T2241-2014) in the light chamber plane size specifications there are more than 21 kinds, each kind of specifications with 2-3 height, the choice design department has more than 50 kinds of wells room.
浇注成型采用塑性混凝土，一般检查井井室成型多为带底一体、2—4个接管开孔，达到脱模强度的养护时间较普通排水管更长，采用蒸汽养护约5—6小时，如果每班生产1520个单规格井室，相比振动成型立即脱模（自然养护）模具用量为,（9~13套模具）：（1套模具+15~20个底托）。浇注成型工艺的模具费用是一笔巨大的支出，此情况较排水管生产悬辊工艺同芯模振动工艺所用模具数量及总体费用相比更严重。
The plastic concrete casting, general inspection wells room for molding with bottom one, 2 - 4 nozzle openings, curing time to demoulding strength than common drain pipe of the steam curing longer, about 5 - 6 hours, if every 1520 single class production specifications wells room, compared to the vibration molding immediately release (natural maintenance dosage (9~13) mold, mold (mold): 1 sets of +15~20 base). The cost of mold for casting process is a huge expense, which is more serious than the number and total cost of the same process.
由于浇注成型工艺生产成本高、达标产能模具用量及费用巨大等原因，一般不用该工艺方式生产常规的批量预制混凝土检查井。
Due to the high cost of casting process, reaching the standard capacity, the large amount of mold and the huge cost, the conventional batch precast concrete inspection well is usually not used.
2、 离心或悬辊成型工艺
2, centrifugal or hanging roll forming process
如筒身与底板间采用胶圈、柔性企口，加以筒、底间预埋张紧连接，产品成本增加（如：右图→）。
For example, the rubber ring and the flexible mouth are used between the barrel and the bottom plate, and the product cost is increased (for example, right map, for example).
排水管生产企业利用原有模具，成型检查井的井筒部分，是一种经济有效的方法。但井室采用二次成型拼装会影响产品质量，井室带孔，离心或悬辊成型时转速不到位或跳模，成品不密实且易发安全事故；如筒身与底板间灌入细石混凝土或砂浆，则由于二者界面收缩不一，产生裂缝；（如：左图←）
It is an economical and effective method to make use of the original mould for the production enterprise of the drainage pipe to form the well bore of the well. But the well chamber two molding assembly will affect the quality of products, the well chamber with a hole, or the centrifugal roller suspension process when the speed is not in place or jump mode, products are not dense and prone to accidents; such as the cylinder body and the bottom plate with fine stone concrete or mortar, because the two shrinkage in a production students (such as: left - crack;)
3、芯模振动成型工艺
3. Vibration molding process of core mold
芯模振动成型工艺采用干法生产，芯模高频整体振动使混凝土液化密实，同时使水泥有一定的活化以提高混凝土强度，混凝土密实度很高，可以立即脱模，大量减少了成型模具数量及总体费用，与湿法工艺相比，可减少原材料的成本和降低人工费用等。
Dry production adopts core mould vibration molding process, the vibration of the whole core frequency to make concrete and cement liquefaction and densification, have certain activation to improve the strength of concrete, concrete density is very high, can immediately release, reduce the number of mold quantity and total cost, compared with the wet process, can reduce the cost of raw materials and reduce labor cost etc..
介绍一种典型的芯模振动生产检查井井室工艺步骤：1.模具在坑内就位；2.内外模间放置排水管孔预埋件、内模顶部放置混凝土托板；3.混凝土布料、振动成型；4. 混凝土超过托板并达到井室底厚度时，碾压；5.放置井室底板并与内模顶部的托板及外模连接；6.成品及外模（含底板及混凝土托板）提出工作坑；7.吊入养护位置，下置养护支撑，脱外模及井室底板；8.养护；9.翻转并脱去混凝土托板及排水管孔预埋件；10.补井室底板与混凝土托板间工作孔；11.至成品堆场。
Introduce a typical core mould vibration production inspection well chamber process steps: 1. die in the pit in place; 2. and die placement of drainage pipe hole is arranged on the top of concrete embedded parts, mold plate; 3. concrete material, concrete plate more than 4. vibration molding; and reach the well chamber bottom thickness, rolling 5. place; well chamber floor and plate and the outer mold and the internal mold at the top of the 6. connection; finished and external mold (including the floor and concrete plate) this pit; 7. into the maintenance position, the maintenance support, and external mold and the well chamber floor; 8. maintenance; 9. flip and stripped off the concrete plate and drainage pipe 10. fill hole hole embedded; work well with concrete floor plate; 11. to finished products yard.
芯模振动生产检查井井室的工艺缺陷：
The process defects of the core mold vibration production check well chamber.
由于芯模振动成型原理方式为激振力横向传递、沿法线方向激振力衰减，在生产井室时底部朝上，井室底部成型须辅以较大的碾压力，井室底部密实度不够；
Because the core mode vibration forming principle is the lateral transfer of exciting force and the attenuation of the exciting force along normal direction, the bottom of the production chamber is upward. The bottom of the well chamber must be reinforced with larger grinding pressure, and the bottom of the well chamber is not dense enough.
养护时井室底部朝上，整体重心偏上，结构不稳，养护支撑高度不易控制，会造成井室底部顶起或轻微坍塌，产生底部裂纹；一般大口径的带底整体井室不用此工艺成型；
During the maintenance, the bottom of the well chamber is upward, the overall center of gravity is upward, the structure is unstable, and the supporting height of maintenance is not easy to control. It will cause the bottom of the well chamber to rise or collapse slightly, resulting in bottom cracks.
为达到立即脱模养护，工艺步骤过多，养护支撑、混凝土托板等模具组件用量也较多；
In order to achieve immediate demoulding maintenance, the process steps are too much, and the amount of mold components such as maintenance support and concrete braces are also more.
养护后的补孔（井室底板与混凝土托板间工作孔）费工费料（一般用掺入树脂的水泥净浆调配）。
Fill the hole after curing (floor and concrete plate between the working hole room) Liu Fei Fei (cement paste mixed with resin by blending).
为减少养护支撑、混凝土托板等模具组件用量过多的问题，国外早期的方法是在内模顶上放置一块塑胶或与混凝土连接性能稍好点的石棉板，使成型后利用井室部分壁厚支撑此板及板上的井室底部混凝土重量，使之不塌陷。
In order to reduce the maintenance support, concrete supportingplate and mould components of excessive amount of problems, early method of foreign is on top of a plastic mold placed or attached to the concrete performance slightly better asbestos point, which is formed by the well chamber wall thickness supporting the plate and plate on the bottom of the well chamber concrete weight. That does not collapse.
此方法会一定程度破坏井室整体结构，板材与混凝土间人为建立诱导缝；配合此脱模养护方法，需井室壁厚尺寸加大，混凝土密实度需充分保证以防止下沉。（如上图 ↑）
This method will destroy the overall structure of the well chamber to some extent, and establish artificial joints between the plank and concrete. If the method is used for the demoulding maintenance, the thickness of the well chamber should be increased, and the density of the concrete must be fully guaranteed to prevent subsidence. (pictured above arrow)
跟据上述情况，芯模振动成型工艺适合生产圆形中小口径井室和各规格井筒，具有生产效率高、产品质量好以及干法生产的其它优势。
According to the above situation, the core mold vibration forming process is suitable for producing circular small and medium-sized well chambers and various specifications of wellbore, and has other advantages such as high production efficiency, good product quality and dry production.
