全体外预应力节段拼装混凝土桥梁设计与施工指南

　 全体外预应力节段拼装混凝土桥梁设计与施工指南

　The Guide for Design and Construction of Precast Segmental Concrete Bridges with External Tendons

　DB ××/T ×××—20××

　 I 目 录

　 前 言 ················································································································ IV 1

　范围 ·························································································································· 1 2

　规范性引用文件 ·········································································································· 1 3

　术语和定义 ················································································································· 1 3.1

　 体外预应力

　 EXTERNAL PRESTRESSING

　·········································································· 1 3.2

　 节段

　 SEGMENT

　······································································································· 1 3.3

　 标准节段

　 STANDARD GIRDER SECTION

　··········································································· 1 3.4

　 转向块节段

　 DEVIATOR GIRDER SECTION

　········································································· 1 3.5

　 横梁节段

　 ANCHORAGE ZONE

　······················································································ 1 3.6

　 胶接缝

　 EPOXY JOINT

　································································································ 2 3.7

　 转向块

　 DEVIATOR

　··································································································· 2 3.8

　 减震装置

　 SHOCK ATTENUATION DEVICE

　········································································· 2 3.9

　 短线匹配预制

　 SEGMENT SHORT - LINE MATCHING METHOD ···················································· 2 3.10

　 匹配节段

　 MATCHING SEGMENT

　·················································································· 2 3.11

　 预制台座

　 TRANSITION ZONE

　····················································································· 2 3.12

　 测量塔

　 SURVEY TOWER

　··························································································· 2 4

　符号 ·························································································································· 2 5

　材料 ·························································································································· 3 5.1

　 混凝土 ·················································································································· 3 5.2

　 钢筋 ····················································································································· 3 5.4

　 接缝连接材料 ········································································································· 4 6

　设计 ·························································································································· 6 6.1

　 一般规定 ··············································································································· 6 6.2

　 总体设计 ··············································································································· 6 6.3

　 构造设计 ··············································································································· 6 6.3.1

　截面设计规定 ··································································································· 6 6.3.2

　节段设计规定 ··································································································· 7 6.3.3

　转向块设计规定 ································································································ 7 6.3.4

　锚固横梁设计规定 ····························································································· 7 6.3.5

　接缝设计规定 ··································································································· 8 6.4

　 体外预应力体系设计 ································································································ 9 6.4.1

　体外束设计规定 ································································································ 9 6.4.2

　转向器设计规定 ······························································································ 10 6.4.3

　锚具设计规定 ································································································· 10 6.4.4

　减震装置设计规定 ··························································································· 10 6.5

　 设计计算 ············································································································· 11 6.5.1

　全体外预应力节段梁设计计算 ············································································ 11 6.5.2

　抗弯承载能力计算 ··························································································· 11 6.5.2.1

　正截面抗弯承载力计算 ················································································ 11

　DB ××/T ×××—20××

　 II 6.5.2.2

　体外预应力钢束的极限应力设计值································································· 12 6.5.2.2.1

　简支梁 ······························································································· 12 6.5.2.2.2

　连续受弯构件 ······················································································ 13 6.5.3

　斜截面承载能力计算 ························································································ 15 6.5.3.1

　斜截面抗剪承载能力验算 ············································································· 15 6.5.3.2

　斜截面抗剪承载能力要求 ············································································· 16 6.5.4

　体外预应力混凝土受弯构件正截面和斜截面抗裂验算 ·············································· 16 6.5.4.1

　构件正截面抗裂性验算 ················································································ 16 6.5.4.2

　构件行斜截面抗裂性验算 ············································································· 16 6.5.5

　体外预应力构件持久状况和短暂状况应力 ····························································· 16 6.5.6

　转向块和锚固横梁按照拉杆——压杆模型计算 ······················································· 16 6.6

　 抗震设计 ············································································································· 17 6.6.1

　总则 ············································································································· 17 6.6.2

　基本要求 ······································································································· 17 6.6.2.1

　全体外预应力节段拼装混凝土桥梁的抗震设防目标 ··········································· 17 6.6.2.2

　地震作用下的抗震设计 ················································································ 17 6.6.2.3

　全体外预应力节段拼装混凝土桥梁的抗震设防标准 ··········································· 18 6.6.2.2.1

　在不同抗震设防烈度下的抗震设防措施等级 ··············································· 18 6.6.2.2.2

　抗震重要性系数 C i

　··············································································· 18 6.6.2.4

　抗震设防烈度和水平向设计基本地震动加速度 ················································· 18 6.6.2.5

　作用效应组合 ···························································································· 18 6.6.3

　地震作用 ······································································································· 18 6.6.4

　建模与分析原则 ······························································································ 19 6.6.5

　性能要求与抗震验算 ························································································ 19 6.6.6

　抗震措施 ······································································································· 20 7

　节段预制 ·················································································································· 20 7.1

　 预制场 ················································································································ 20 7.2

　 模板工程 ············································································································· 20 7.3

　 钢筋工程 ············································································································· 20 7.4

　 构件预制与养生 ···································································································· 21 7.5

　 构件标志与存放 ···································································································· 22 7.6

　 质量检查与质量标准 ······························································································ 22 8

　节段安装 ·················································································································· 23 8.1

　 节段出厂与运输 ···································································································· 23 8.2

　 节段安装 ············································································································· 23 8.2.1

　节段安装设备的选择 ························································································ 23 8.2.2

　安装设备 ······································································································· 24 8.2.3

　节段起吊与悬挂 ······························································································ 24 8.2.4

　节段定位 ······································································································· 24 8.2.5

　节段环氧胶接缝施工 ························································································ 24 8.2.6

　节段安装用临时预应力 ····················································································· 24 8.3

　 湿接缝施工 ·········································································································· 25 8.4

　 体外预应力安装 ···································································································· 25 8.5

　 质量检查与质量标准 ······························································································ 25

　DB ××/T ×××—20××

　 III 9

　测量与施工控制 ········································································································ 26 9.1

　 一般规定 ············································································································· 26 9.2

　 预制施工测量 ······································································································· 26 9.2.1

　节段预制测量控制网 ························································································ 26 9.2.2

　短线匹配预制工艺 ··························································································· 26 9.2.3

　控制点及台座高程点的高程应定期校核 ································································ 27 9.2.4

　节段预制定位测点布置 ····················································································· 27 9.2.5

　预埋点平面坐标及高程测量 ··············································································· 27 9.3

　 架设施工测量 ······································································································· 28 9.4

　 施工控制 ············································································································· 28 10

　质量检验与评定 ······································································································· 29 10.1

　 一般规定 ··········································································································· 29 10.2

　 钢筋工程 ··········································································································· 30 10.2.1

　基本要求 ····································································································· 30 10.2.2

　检验项目 ····································································································· 30 10.2.3

　外观鉴定 ····································································································· 30 10.3

　 构件浇筑 ··········································································································· 30 10.3.1

　基本要求 ····································································································· 30 10.3.2

　检验项目 ····································································································· 30 10.3.3

　外观鉴定 ····································································································· 31 10.4

　 节段拼装 ··········································································································· 31 10.4.1

　基本要求 ····································································································· 31 10.4.2

　检验项目 ····································································································· 31 10.4.3

　外观评定 ····································································································· 32

　DB ××/T ×××—20××

　 IV 前 言

　 本标准按照 GB/T 1.1—2009 给出的规则起草。

　本标准提出单位：××。

　本标准归口单位：××。

　本标准起草单位：××。

　本标准主要起草人：

　DB ××/T ×××—20××

　 1 全体外预应力节段拼装混凝土桥梁设计与施工指南

　1

　范围 本标准规定了体外预应力节段预制拼装桥梁的术语、符号、设计、施工、质量验收等要求。

　本标准适用于公路全体外预应力节段拼装混凝土桥梁设计与施工，其他体外预应力与节段拼装桥梁工程可参照使用。

　2

　规范性引用文件 下列文件对于本文件的应用是必不可少的，凡是注日期的引用文件，仅注日期的版本适用于本文件。凡是不注日期的引用文件，其最新版本（包括所有的修改单）适用于本文件。

　JTG B01 公路工程技术标准 JTG D30 公路路基设计规范 JTG D60 公路桥涵设计通用规范 JTG D61 公路圬工桥涵设计规范 JTG D62 公路钢筋混凝土及预应力混凝土桥涵设计规范 JTG D63 公路桥涵地基与基础设计规范 JTG F50 公路桥涵施工技术规范 JTG F80 公路工程质量检验评定标准（第一册土建工程）

　JTG/T B02 公路桥梁抗震设计细则 3

　术语和定义 下列术语和定义适用于本标准。

　3.1

　体外预应力

　external prestressing 一种布置在混凝土梁体截面之外，锚固在横梁上，通过张拉为结构提供预压应力的钢束。

　3.2

　节段

　segment 桥梁沿结构长度方向划分后形成的预制单元，根据其功能不同可分为标准节段、转向块节段和横梁节段等。

　3.3

　标准节段

　standard girder section 不含转向块和横梁等锚索结构的节段，具有统一的截面和长度。

　3.4

　转向块节段

　deviator girder section 为体外束提供转向的节段，节段内可设置一个或多个转向块。

　3.5

　横梁节段

　anchorage zone 位于墩顶位置，为体外束提供转向及锚固的节段。

　DB ××/T ×××—20××

　 2 3.6

　胶接缝

　epoxy joint 混凝土预制构件结合面涂抹环氧树脂胶后拼接的接缝。

　3.7

　转向块

　deviator 预埋体外预应力转向装置，辅助体外预应力弯起、转向，承受体外预应力束转向产生径向力的肋式或块式结构。

　3.8

　减震装置

　shock attenuation device 用于缓解体外索振动的辅助设施。

　3.9

　短线匹配预制

　segment short-line matching method 在台座上用固定的模板，依次将已浇筑好的节段作为匹配节段，逐段匹配、流水制作节段的预制施工方法。

　3.10

　匹配节段

　matching segment 在短线匹配预制过程中，用于辅助待浇筑节段定位和制造的已完成节段。

　3.11

　预制台座

　transition zone 提供节段预制操作的平台。

　3.12

　测量塔

　survey tower 搭建在预制台座旁边，用于辅助节段预制定位测量的永久测站。

　4

　符号 下列符号适用于本标准。

　e , PbA ——斜裂缝范围内体外弯起预应力钢筋的截面面积 e PA ——体外预应力钢束的截面设计值 SVA ——斜裂缝范围内一个间距内箍筋各肢的总截面面积 e Pdf,——体外预应力钢束的极限应力设计值 1C ——接缝影响系数 1 ——异号弯矩影响系数  ——体内外预应力配筋的影响系数  ——截面形状影响系数 P ——纵向配筋率 m ——剪跨比

　DB ××/T ×××—20××

　 3 C ——斜裂缝的水平投影长度 vS ——斜裂缝范围内的箍筋间距

　svf ——箍筋的抗拉强度设计值 i Pdf, ——体内预应力钢筋的抗拉强度设计值 i PbA,——斜裂缝范围内体内弯起预应力钢筋的截面面积 e Pd, ——体外预应力钢筋的极限应力设计值 e Puh,——体外预应力钢束合力点至截面受压边缘的距离 i PA,——体内预应力钢束的截面面积 i Pdf,——体内预应力钢束的抗拉强度设计值 i Ph,——体内预应力钢束合力点至受压边缘的距离 sA ——体内纵向受拉普通钢筋的面积 sdf ——体内纵向受拉普通钢筋的抗拉强度设计值 sh ——体内纵向受拉普通钢筋至截面受压边缘的距离 ,sA ——体内纵向受压普通钢筋的面积 ,sdf ——体内纵向受压普通钢筋的抗压强度设计值 ,sh ——体内纵向受压普通钢筋至截面受压边缘的距离 5

　材料 5.1

　混凝土 5.1.1

　节段预制拼装混凝土构件用混凝土强度等级不应低于 C40。

　5.1.2

　节段预制拼装混凝土桥梁用混凝土材料性能应符合《公路钢筋混凝土及预应力混凝土桥涵设计规范》D62 的有关规定。

　5.2

　钢筋 5.2.1

　节段预制拼装混凝土构件用普通钢筋宜采用采用 HPB300、HRB400、HRB500、HRBF400、HRBF500、RRB400 和 RRB500 钢筋，并应符合现行国家标准《钢筋混凝土用钢第 1 部分：热轧光圆钢筋》GB 1499.1、《钢筋混凝土用钢第 2 部分：热轧带肋钢筋》GB 1499.2、《钢筋混凝土用余热处理钢

　DB ××/T ×××—20××

　 4 筋》GB 13014 的有关规定。

　5.2.2

　节段预制拼装混凝土构件用普通钢筋的抗拉强度标准值应具有不小于 95%的保证率。普通钢筋的抗拉强度标准值 fsk 应按表 1 采用。

　表 1 普通钢筋抗拉强度标准值 钢筋种类 符号 公称直径 d（mm）

　fsk（MPa）

　HPB300 

　6～22 300 HRB400

　 6～50 400 HRBF400

　RRB400

　HRB500

　 6～50 500 HRBF500

　 RRB500

　5.2.3

　节段预制拼装混凝土构件用普通钢筋的抗拉强度设计值 fsd 和抗压强度设计值 f’sd 应按表 2 采用。

　表 2 普通钢筋抗拉、抗压强度设计值 钢筋种类 公称直径 d（mm）

　fsd（MPa）

　f’sd（MPa）

　HPB300 6～22 250 250 HRB400 6～50 330 330 HRBF400 RRB400 HRB500 6～50 415 400 HRBF500 RRB500 5.2.4

　节段预制拼装混凝土桥梁采用不锈钢钢筋和环氧树脂涂层钢筋时，应符合现行行业标准《钢筋混凝土用不锈钢钢筋》YB/T 4362 和《环氧树脂涂层钢筋》JG 3042 的规定。

　5.3

　预应力 5.3.1

　节段预制拼装混凝土桥梁用体内预应力相关材料性能应符合《公路钢筋混凝土及预应力混凝土桥涵设计规范》D62 的规定。

　5.3.2

　节段预制拼装混凝土桥梁用体外预应力应采用无粘结预应力钢绞线，相关技术指标应满足现行行业标准《无粘结预应力钢绞线》JG 161 和《无粘结钢绞线体外预应力束》JT/T 853 的规定。

　5.3.3

　体外预应力用无粘结钢绞线可采用环氧涂层钢绞线或镀锌钢绞线，其材料性能及防腐特性应满足下列要求：

　1

　环氧涂层钢绞线应符合国家现行标准《环氧涂层七丝预应力钢绞线》GB/T 21073、 《单丝涂覆环氧涂层预应力钢绞线》GB/T 25823 和《环氧涂层预应力钢绞线》JG/T387、 《填充型环氧涂层钢绞线体外预应力束》JT/T 876 的规定。

　2

　镀锌钢绞线应符合现行行业标准《镀锌钢绞线》YB/T 5004 和《高强度低松弛预应力热镀锌钢绞线》YB/T 152 的规定。

　5.4

　接缝连接材料 5.4.1

　全体外预应力节段预制拼装混凝土桥梁宜采用环氧树脂胶接缝。

　DB ××/T ×××—20××

　 5 5.4.2

　预制节段接缝采用环氧树脂胶时，其胶体性能及粘结能力应符合表 3 的规定。

　表 3 环氧树脂胶主要性能要求 性能项目 性能要求 试验方法标准 物理性能 可施胶时间（min）

　≥20 GB/T 7123 可粘结时间（min）

　≥60，且≤240 GB/T 12954 固化速度（低限温度条件）

　12 小时抗压强度（MPa）

　≥40

　GB/T 17671 24 小时抗压强度（MPa）

　≥60 7 天抗压强度（MPa）

　≥80 压缩弹性模量*（MPa）

　瞬时 ≥8000

　GB/T 17671 1 小时 ≥6000 剪切弹性模量*（MPa）

　瞬时 ≥1500

　1 小时 ≥1200

　在结构立面上无流挂现象的最大涂胶层厚度（mm）

　≥3

　不挥发物含量（固体含量）（%）

　≥99 GB/T 2793 吸水率（高限温度条件）（%）

　≤0.5%

　水中溶解率（高限温度条件）（%）

　≤0.1%

　高限温度 条件固化 7 天的热变 形温度（℃ ）

　0℃≤适用温度＜10℃ 45 GB/T 2793 10℃≤适用温度＜30℃ 50 30℃≤适用温度＜60℃

　60 伸长率（%）

　≥1.0 GB/T 2567 力学性能 抗压强度（MPa）

　≥80 GB/T 17671 钢-钢拉伸抗剪强度标准值（MPa）

　≥14 GB/T 7124 与混凝土的正拉粘结强度（MPa）

　≥3.0， 且为混凝土内聚破坏 JG/T 157 化学性能 耐湿热老化性 50℃温度、95%相对湿度的环境条件下老化 90d 后，常温条件下钢-钢拉伸抗剪强度降低率 ≤10% GB/T 50728 耐盐雾性 5%氯化钠溶液、喷雾压力 0.08MPa、试验温度（35±2）℃、每 0.5h 喷雾一次、每次 0.5h、作用持续时间 90d，到期钢-钢拉伸抗剪强度降低率 ≤5%，且不得有裂纹或脱胶 GB/T 50728

　DB ××/T ×××—20××

　 6 6

　设计 6.1

　一般规定 6.1.1

　本指南采用极限状态设计方法，桥梁结构的设计基准期为 100 年。

　6.1.2

　全体外预应力节段预制拼装混凝土桥梁的设计除应符合本标准的有关规定外，尚应符合《公路桥涵通用设计规范》JTG D60，《公路钢筋混凝土及预应力混凝土桥涵设计规范》JTG D62 及《公路桥涵地基与基础设计规范》JTG D63 等现行国家及行业标准的规定。

　6.1.3

　桥梁主体结构的设计使用年限不应低于 100 年。体外预应力钢索应可更换，设计使用年限不应低于 25 年。

　6.1.4

　全体外预应力节段拼装混凝土桥属于特殊桥梁，本指南只给出设计原则。

　6.1.5

　桥梁抗震设计除应符合本指南第 6.6 条的规定外，尚应符合现行行业标准《公路桥梁抗震设计细则》JTG/T B02. 6.1.6

　节段预制拼装混凝土桥梁应根据结构特点、使用年限、环境条件、施工条件等进行耐久性设计。耐久性设计应包括下列内容：

　6.1.6.1

　确定结构和结构构件所处的环境类别及其作用等级； 6.1.6.2

　提出对混凝土材料的耐久性基本要求，以确保结构的耐久性； 6.1.6.3

　明确构件中钢筋的混凝土保护层厚度； 6.1.6.4

　不同环境条件下的耐久性技术措施； 6.1.6.5

　接缝部位的耐久性技术措施； 6.1.6.6

　采用有助于耐久性的结构构造，便于施工、检修和维护管理；采取适当的施工养护措施，满足耐久性所需的施工养护的基本要求； 6.1.7

　节段预制拼装混凝土桥梁应设置检修通道，检修通道应满足检修、养护及部件更换的空间需求。

　6.2

　总体设计 6.2.1

　设计基本原则 6.2.1.1

　桥梁设计安全等级应符合现行行业标准《公路桥涵设计通用规范》JTG D60 的相关规定； 6.2.1.2

　桥梁应根据所处环境条件进行耐久性设计，具体要求应符合现行行业标准《公路钢筋混凝土及预应力混凝土桥涵设计规范》JTG D62 的相关规定； 6.2.1.3

　桥梁应综合考虑预制、拼装工艺，以设计、施工一体化为设计目标。

　6.2.2

　结构选型与跨径布置 6.2.2.1

　桥梁总里程超过 3km 时，可采用全体外预应力节段预制拼装连续梁桥，以保证桥梁建设经济性； 6.2.2.2

　节段梁桥应采用等高、等跨布置形式，以减少预制节段类型，保证工厂预制效率； 6.2.2.3

　节段梁跨径应小于 100m，采用逐跨拼装工艺时，跨径应尽量选择在 60m 以内，选择悬臂拼装工艺时，跨径应选在 50～100m 范围内。

　6.3

　构造设计 6.3.1

　截面设计规定 6.3.1.1

　全体外预应力节段梁截面设计宜采用斜腹板箱形截面，以减小底板自重。

　6.3.1.2

　节段预制拼装箱梁桥除横梁和转向块外，宜采用等截面设计，以提高标准化程度。

　6.3.1.3

　节段预制拼装箱梁顶板厚度及构造应满足纵向受力、横向受力及横向预应力钢筋布置要求，且厚度不宜小于 220mm。

　DB ××/T ×××—20××

　 7 6.3.1.4

　节段预制拼装箱梁底板厚度及构造应满足纵向受力、横向受力要求，且厚度不宜小于 200mm。

　6.3.1.5

　节段拼装箱梁腹板厚度不宜小于 200mm。

　6.3.1.6

　箱梁翼缘板较宽时，可通过设置肋板，增加翼缘板刚度，改善结构横向受力。

　 图 1 带肋翼缘板示意图 6.3.2

　节段设计规定 6.3.2.1

　全体外预应力节段预制拼装梁桥节段可分为标准节段、转向块节段、横梁节段。

　6.3.2.2

　预制节段划分应综合考虑桥梁跨径、横梁尺寸、转向块位置等因素确定，标准节段长度宜为 3m。

　6.3.2.3

　转向块节段长度宜与标准节段保持一致，转向块距节段端部净距不宜小于 0.5m。

　6.3.2.4

　横梁节段长度应满足体外束锚固尺寸要求，单个横梁节段重量不宜大于标准节段重量的 1.5 倍，当不满足要求时，可分段设计。

　6.3.2.5

　横梁节段两侧应设置湿接缝，湿接缝宽度宜为 100mm～200mm。

　6.3.3

　转向块设计规定 6.3.3.1

　全体外预应力节段预制拼装桥梁转向块宜采用肋式转向块。

　6.3.3.2

　当结构体外预应力较多时，体外预应力束可采用竖向双层布置形式，包括错层布置和平行布置。

　图 2 转型管道双层布置 6.3.3.3

　转向块内应设置内环筋和外封闭箍筋，参见图 3，内环筋和外封闭箍筋沿转向器长度方向的间距不宜小于 100mm，内环筋与转向器上缘之间的净距离宜不小于 25mm，直径≤20mm；外封闭箍筋在竖向与内环筋的净距宜不小于 50...