House Prefabricated Beam Process

The typical process for prefabricating beams in houses can be divided into three types based on different production scenarios: intelligent assembly line prefabrication, box girder prefabrication construction, and prefabricated construction for assembled buildings. Details are as follows:

I. Intelligent Assembly Line Prefabrication Beam Yard Process
This process relies on an automated production line, with core areas including steel bar binding, concrete pouring, and steam curing zones. First, the bottom and web reinforcement bars are bound on a steel bar jig to form an integral reinforcement cage, which is then hoisted to the concrete pouring zone. Simultaneously, the internal mold is installed and the top reinforcement bars are fixed. Concrete is transported from the mixing plant to the distribution machine via torpedo tanks and fills the mold using a layered pouring method to ensure compactness. After the beam strength reaches 80% of the design value, the mold is removed, and the beam is transferred by a mobile trolley to the steam curing room for steam curing, with the temperature controlled at 50-60℃ for 6-8 hours to accelerate the concrete hydration reaction. After curing, prestressed tensioning and grouting operations are performed, applying the design tension through a jack and injecting high-strength cement grout. Finally, the beam is lifted to the beam storage area using a gantry crane.

II. Box Girder Prefabrication Construction Process
During the construction preparation phase, the foundation treatment of the pedestal and material inspection must be completed to ensure the foundation bearing capacity meets the requirements. In the steel bar processing stage, CNC machine tools are used for cutting, and the steel bars are bound into shape on a dedicated pedestal according to the design drawings, with a focus on controlling the positional accuracy of embedded pipes and fittings. Mold installation follows the sequence of 'bottom mold first, side mold next, and then internal mold,' with a water-based release agent applied to reduce the risk of mold adhesion. Concrete pouring adopts a layered and segmented advancing method, with each layer not exceeding 30cm in thickness, and is vibrated using a combination of high-frequency attached vibrators and immersion vibrators to avoid honeycomb and pitted surfaces. After pouring, plastic film is used for moist curing, and after the strength reaches the standard, the mold is removed and the surface is trimmed.

III. Production Process for Prefabricated Beams in Assembled Buildings
Before pouring, the mold gaps must be sealed with sealing strips to prevent grout leakage; concrete is distributed using a gantry crane to hoist the concrete hopper, and vibrated densely with a high-frequency vibrator. After pouring, the surface is smoothed, and a top baffle mold is installed, with a QR code label containing production information embedded. During the steam curing stage, the beam is moved into the steam curing shed, and the temperature is raised in stages (not exceeding 15℃ per hour) through an intelligent temperature control system, with a constant temperature stage maintained at 60℃±2℃ for 12 hours. During demolding, a duckbill hoist is used to connect to the pre-embedded lifting pins on the beam, and the beam is lifted to a height of 200-300mm to check the connection firmness before formal transfer. Rubber pads or steel supports must be placed under the component to prevent damage. After production, residual concrete in the mold is cleaned, and tools and drawings are stored separately in preparation for the next production cycle.