宁波舟山港主通道一体式钢管桩制造技术

宁波舟山港主通道工程70m跨非通航孔主桥和62.5m跨非通航孔引桥采用螺旋焊缝钢管桩(每根桩上、下部分壁厚不同),桩径分1.6m、1.8m、2m三种规格,最大桩长109m。针对钢管桩大直径、超长、不等壁厚等特点,钢管桩采用全自动化整桩螺旋卷制生产制造方案。制造过程中,将2根桩相同壁厚部分连起来制造,采用在线预精焊、全自动激光跟踪扫描智能化纠偏焊接技术、钢带对接外焊缝自动焊接设备和剪力环自动焊接专用机器设备,建立大直径、超长钢管桩全自动化生产线,实现钢管桩高质、快速制造。该技术的应用,使钢管桩焊接质量一次检测合格率达99.5%以上,加工效率提高2.5倍,仅用16个月,完成了24万吨钢管桩的制造。

Manufacturing Technology for Integrated Steel Tubular Piles of Ningbo-Zhoushan Port Main Corridor

In the Ningbo-Zhoushan Port Main Corridor,the non-navigable approach bridge with spans of 62.5 mand the non-navigable approach bridge with spans of 70 mhave pier foundations formed of steel tubular piles with spiral welds and with three different diameters of 1.6 m,1.8 mand 2 m.The piles are not constant in wall thickness,for each pile,the upper walls do not match with the lower walls in terms of thickness.The pile stretches down to a maximum depth of109 m.Based on the characteristics of the steel tubular piles,like large diameter,magnificent length and variable wall thickness,an automated manufacturing scheme is adopted,in which each pile is integrally-fabricated and spirally rolled to take shape.In the manufacturing process,the sections of every two piles with the same thickness were manufactured together.The intelligent deviation correction welding technique that allows for on-line accurate pre-welding and automatic laser tracking and scanning was employed.And the manufacturing equipment was connected with the external automatic welding setup and the exclusive device for automatic welding of shear rings.to build the fully automatic manufacturing line for the realization of high-quality and rapid manufacturing of the large-diameter and very long steel tubular piles.By using the technique mentioned,the welding qualification rate of steel tubular piles from one-time inspection was above 99.5%and the manufacturing efficiency was improved by 2.5 times.The manufacture of the 240 000 tsteel tubular piles was finished in only 16 months.