CN111730727B

CN111730727B - Manufacturing method of vertical prefabricated template of underground comprehensive pipe gallery

Info

Publication number: CN111730727B
Application number: CN202010566693.6A
Authority: CN
Inventors: 蔡清程; 陈武; 吴建娃; 许艺杰
Original assignee: Cccc Sanya Xiamen Engineering Co ltd; Xiamen Sanhang Concrete Co ltd; CCCC Third Harbor Engineering Co Ltd; CCCC Third Harbor Engineering Co Ltd Xiamen Branch
Current assignee: Cccc Third Aviation Bureau Sixth Engineering Xiamen Co Ltd; Xiamen Sanhang Concrete Co ltd; CCCC Third Harbor Engineering Co Ltd; CCCC Third Harbor Engineering Co Ltd Xiamen Branch
Priority date: 2020-06-19
Filing date: 2020-06-19
Publication date: 2021-06-11
Anticipated expiration: 2040-06-19
Also published as: CN111730727A

Abstract

The invention discloses a method for manufacturing a vertical prefabricated template of an underground comprehensive pipe gallery. The bottom die manufacturing step sequentially comprises bottom die manufacturing, primary impression manufacturing and secondary impression manufacturing; when the bottom tire mold manufacturing procedure is carried out, assembling a bottom tire mold frame on the leveling steel plate; when a primary impression making procedure is carried out, a primary impression steel frame is assembled on the top surface of the bottom tire mold by adopting an impression process, and then the primary impression steel frame is filled with pouring concrete; when the secondary impression making procedure is carried out, an impression process is adopted, a secondary impression steel frame is assembled on the top surface of the primary impression, and then the secondary impression steel frame is filled with pouring concrete; and when the top die is manufactured, a stamping process is adopted, namely a top die steel frame is assembled on the top surface of the bottom die, and then the top die steel frame is filled with pouring concrete. The invention can ensure perfect butt joint between adjacent pipe gallery segments.

Description

Manufacturing method of vertical prefabricated template of underground comprehensive pipe gallery

Technical Field

The invention relates to a method for manufacturing a vertical prefabricated template of an underground comprehensive pipe gallery.

Background

The utility tunnel is a public tunnel space which is constructed underground in a city, intensively lays municipal public pipelines such as water, heat, gas, electric power, communication and the like in a structure and implements unified planning, design, construction and management. The utility tunnel can realize once excavation, and the repeated construction of same highway section, repeated excavation are avoided in the concentrated construction. In utility tunnel work progress, often can lead to traffic jam because of the construction, influence resident's normal life. The construction process of the comprehensive pipe gallery generally adopts a long-line matching prefabrication method, namely, the end face of a poured pipe gallery segment is used as a front end mould of a pipe gallery segment to be poured, and a matching joint is formed in such a way to ensure the matching precision between two adjacent pipe gallery segments. When the pipe gallery is assembled, the cross section is taken as a unit, gluing and assembling between the adjacent pipe gallery sections are firstly carried out on site, then the temporary prestress is used for fixing, and finally the permanent prestress is used for tensioning, so that the installation of the cross-section pipe gallery is completed (see figure 1).

The long line matching prefabrication process determines that prefabrication of the pipe gallery can only be horizontal prefabrication, namely the prefabrication direction of the pipe gallery is parallel to the installation direction of the pipe gallery, and prefabrication of each pipe gallery segment in the span can only be completed by taking the span as a unit in sequence, so that the process also has the following limitations:

(1) because the height of the large-section pipe gallery is generally higher and is more than 4 meters, the pouring and blanking height of the concrete of the wall body of the pipe gallery is too high, so that the concrete is easy to segregate, the concrete bleeding is finally caused, sand spots appear on the appearance, even the phenomena of honeycombs, holes and the like appear, the pouring quality of the concrete is not easy to control, and the quality defect is easy to appear; the adoption of auxiliary blanking tools such as chutes or serial drums has low actual operability due to the dense steel bars, and is difficult to control;

(2) the span of the cabin of the large-section multi-cabin pipe gallery is 2-6 meters, the formwork removing strength of the inner formwork is required according to the specification, the concrete strength must reach 80% of the design strength, the formwork can be removed, the use efficiency of the formwork and the pedestal is greatly limited, the strength requirement can be met in 4-5 days, and if the temperature is low in winter, the formwork removing time is longer, and the construction period is greatly influenced. If steam maintenance is adopted, the sealing between the pipe gallery sections which are connected in a matching mode is difficult to guarantee; in addition, steam curing has certain destructive effect on the concrete structure, and is not environment-friendly and economical, and consumes larger cost. The steam curing cost of the cubic concrete is nearly 100 yuan;

(3) the process takes the span as a unit, each pipe gallery segment in the span has uniqueness, the pipe gallery segment cannot be interchanged with pipe gallery segments of other spans, and even if the pipe gallery segments are the same span, the position sequence cannot be changed. Therefore, the application of the pipe gallery segments is greatly limited and inflexible, and the stacking, transportation and prefabrication period of the pipe gallery segments are also affected little;

(4) the current pipe gallery structure develops towards the direction of a plurality of cabins and a large section, and has high height and large span. The steel consumption of the movable inner die part adopted by the long-line matching prefabrication process is greatly increased, and the steel consumption of a single movable inner die support reaches about 12 tons.

The short-line prefabricating method has the advantages that the field is relatively small, the length of the pedestal is only three sections, and the pouring template and the pouring equipment do not need to move basically. Not only the negative influence on traffic operation in the construction process of the project is reduced, but also the construction period is finally shortened, and the construction economic benefit is improved. The key of the short-line vertical prefabrication method is the prefabrication template process of the pipe gallery, the precision of the prefabrication template must reach a higher level, the perfect butt joint of the seams of adjacent sections is ensured, and the tight joint is achieved, namely the method is equivalent to matching the prefabricated seams.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provide the method for manufacturing the vertical prefabricated template of the underground comprehensive pipe gallery, which can control the quality of all bottom moulds and top moulds, has high precision of the manufactured prefabricated template and is suitable for large-scale and large-batch prefabrication of large-section pipe gallery segments in a factory.

The purpose of the invention is realized as follows: a method for manufacturing a vertical prefabricated template of an underground comprehensive pipe gallery comprises the steps that the pipe gallery is formed by splicing a multi-span double-cabin pipe gallery, and each span of the double-cabin pipe gallery comprises a head-end pipe gallery section, a plurality of standard pipe gallery sections and a tail-end pipe gallery section which are sequentially connected through shear keys; the front end surface of the head end pipe gallery segment is provided with a concave shear key, and the rear end surface of the head end pipe gallery segment is a plane and exposes a reinforcing steel bar and a water stop steel plate which are used for being connected with the cast-in-place segment; a convex shear key matched with the shear key on the front end face of the head end pipe gallery section is arranged on the rear end face of each standard pipe gallery section, and a concave shear key is arranged on the front end face of each standard pipe gallery section; the rear end face of the tail end pipe gallery section is provided with a convex shear key matched with the shear key on the front end face of the standard pipe gallery section, and the front end face of the tail end pipe gallery section is a plane and is exposed with a steel bar and a water stop steel plate which are used for being connected with the cast-in-place section; all the pipe gallery sections comprise bottom plates, top plates, left side plates, partition walls and right side plates; the manufacturing method of the prefabricated template comprises a bottom die manufacturing step, a top die manufacturing step, an outer die manufacturing step, an inner die manufacturing step and a template assembling step; wherein the content of the first and second substances,

the bottom die manufacturing step sequentially comprises the following steps: manufacturing a bottom moulding bed, manufacturing a primary impression and manufacturing a secondary impression;

when a bottom tire mold manufacturing procedure is carried out, assembling a bottom tire mold of a steel frame structure with the plane shape matched with the cross section shape of the pipe gallery on the leveling steel plate, wherein the bottom tire mold comprises a top plate bottom tire mold frame, a bottom plate bottom tire mold frame, a left side plate bottom tire mold frame, a partition wall bottom tire mold frame and a right side plate bottom tire mold frame; the partition wall bottom tire die frame comprises two partition wall main body channel steels which are vertically arranged oppositely, a plurality of partition wall transverse connection channel steels which are fixed between the two partition wall main body channel steels at intervals, and a partition wall steel plate strip which is fixed on the top surfaces of the two partition wall main body channel steels; the other bottom tire mold frames comprise bottom tire mold frame main bodies and a plurality of shear key boxes; the bottom die frame main body comprises two main body channel steels which are vertically arranged oppositely, a plurality of transverse connection channel steels which are fixed between the two main body channel steels at intervals and a steel plate belt which is fixed on the top surfaces of the two main body channel steels, and a plurality of box holes which are matched with the top outer contour of the shear key box are formed in the steel plate belt at positions corresponding to the shear keys; the plurality of shear key boxes are correspondingly arranged in the plurality of box holes one by one; the positions of four corners on the top surface of the bottom matrix, which correspond to the corrugated pipes, are respectively provided with a circular hole for embedding the magnet sheet;

when a primary impression making procedure is carried out, an impression process is adopted, a bottom mould is leveled firstly, then a primary impression steel frame is assembled on the top surface of the bottom mould, the plane shape and the size of the primary impression steel frame are consistent with those of the bottom mould, and the primary impression steel frame comprises a top plate bottom mould frame, a bottom plate bottom mould frame, a left side plate bottom mould frame, a partition wall bottom mould frame and a right side plate bottom mould frame; all the bottom die frames comprise two main body channel steels which are vertically arranged oppositely, a plurality of transverse connection steel bars which are fixed between the two main body channel steels at intervals and a steel plate belt which is fixed on the bottom surfaces of the two main body channel steels, and holes matched with the top profiles of the shear key boxes on the bottom die are formed in the steel plate belt; filling pouring concrete in the primary die steel frame and the shear key box, and compacting by vibration to form a primary die of a steel concrete structure with convex shear keys; when concrete is filled, a round magnet piece is respectively embedded in the position of the four corners of the primary impression corresponding to the corrugated pipe;

when a secondary impression making procedure is carried out, an impression process is adopted, a primary impression is turned over for 180 degrees and placed on a leveling steel plate for leveling, then a secondary impression steel frame is assembled on the top surface of the primary impression, the plane shape and the size of the secondary impression steel frame are consistent with those of the primary impression steel frame, the making method of the secondary impression steel frame is the same as that of the primary impression steel frame, then concrete is filled between the inside of the secondary impression steel frame and the top surface of the primary impression and is vibrated to be compact, and the secondary impression with a concave shear key steel concrete structure is formed; when concrete is filled, a round magnet piece is respectively embedded in the position of the four corners of the secondary impression corresponding to the corrugated pipe;

the top die manufacturing step is carried out by adopting a die stamping process, namely a top die steel frame is assembled on the top surface of the bottom die, the plane shape and the size of the top die steel frame are consistent with those of the bottom die and comprise a top plate top die frame, a bottom plate top die frame, a left side plate top die frame, a partition wall top die frame and a right side plate top die frame; all the top die carriers comprise two main bodies and a plurality of transverse connections connected between the two main bodies; each main body and the transverse connection are formed by welding two channel steels in a surrounding manner; a temporary support channel steel is respectively arranged between the bottom surface of each main body and the top surface of the bottom moulding bed; respectively placing a shear key cylinder matched with the top contour of the shear key box on each shear key box on the top plate top die frame, the bottom plate top die frame, the left side plate top die frame and the right side plate top die frame, and filling and pouring concrete in each shear key cylinder and each shear key box and compacting the concrete by vibration so as to enable the concrete in each shear key cylinder to be respectively and transversely connected and consolidated into a whole;

when the outer mold manufacturing step is carried out, a top plate outer mold plate, a bottom plate outer mold plate, a left side plate outer mold plate and a right side plate outer mold plate which are of a whole piece type are adopted, and all the outer mold plates comprise an L-shaped outer mold panel with an arc-shaped corner, a plurality of horizontal ribs which are uniformly fixed on the back of the outer mold panel at intervals and a plurality of vertical ribs which are uniformly fixed on the horizontal ribs at intervals;

when the internal mold manufacturing step is carried out, eight integral type internal mold plates which are L-shaped and have chamfered corners are adopted, namely a pair of left cabin top side internal mold plates, a pair of left cabin bottom side internal mold plates, a pair of right cabin top side internal mold plates and a pair of right cabin bottom side internal mold plates; the pair of left cabin top side inner formworks and the pair of left cabin bottom side inner formworks are connected through pin bolts to form a pipe gallery left cabin inner formwork; the pair of right cabin top side inner formworks and the pair of right cabin bottom side inner formworks are connected through pin bolts to form a pipe gallery right cabin inner mould; a hydraulic oil cylinder is connected between the middle parts of the left cabin top side inner formworks and the middle parts of the right cabin top side inner formworks; all the inner templates comprise inner template panels, a plurality of horizontal ribs fixed on the back of the inner template panels at consistent intervals and a plurality of vertical ribs fixed on the horizontal ribs at consistent intervals;

when the prefabricated formwork assembling step is carried out, the outer formwork is assembled, namely the top plate outer formwork and the left side plate outer formwork and the right side plate outer formwork as well as the bottom plate outer formwork and the left side plate outer formwork and the right side plate outer formwork are spliced and fastened through 45-degree diagonal draw bars; and then, the outer die is installed on the bottom die, namely the bottom of the vertical rib of each outer die plate is connected with the corresponding bottom die through a diagonal draw bar, the inner die is installed on the inner side of the bottom die, namely the bottom of the vertical rib of each inner die plate is connected with the corresponding bottom die through a diagonal draw bar, then the top die is hoisted in place, namely the top die is placed between the top of the inner die and the top of the outer die, the upper part of the vertical rib of each inner die plate and the upper part of the vertical rib of the corresponding outer die plate are connected in a split-pull mode through a brace, so that the top of the inner die and the top of the outer die clamp the top die, and the elevation of the top die is controlled through.

According to the manufacturing method of the vertical prefabricated template of the underground comprehensive pipe gallery, the outer side surfaces of all the outer templates are connected with a working platform made of square steel.

According to the manufacturing method of the vertical prefabricated template of the underground comprehensive pipe gallery, the outer die panel and the inner die panel are made of steel plates with the thickness of 8mm, the horizontal ribs are made of No. 8 channel steel, and the vertical ribs are made of No. 18 channel steel.

The manufacturing method of the vertical prefabricated template of the underground comprehensive pipe gallery has the following characteristics: the bottom die and the top die are manufactured by adopting a die copying process, namely the bottom die with the concave shear key after molding, the bottom die with the convex shear key after molding, the top die with the concave shear key after molding and the top die with the convex shear key after molding are derived and copied from the same bottom moulding bed, so that the quality of all the bottom die and the top die can be well controlled, the manufactured prefabricated template has high precision, is suitable for large-scale and large-scale prefabrication of large-section pipe gallery segments in factories, and is environment-friendly and economical. Each pipe gallery segment prefabricated by the prefabricated template manufactured by the manufacturing method has interchangeability, can be freely combined according to the actual length of each span of the pipe gallery on site, ensures that the adjacent pipe gallery segments can be perfectly butted, and realizes tight seaming, namely the joint is equivalent to matching the prefabricated joint.

Drawings

FIG. 1 is a cross-sectional view of a vertical prefabricated form prefabricated pipe gallery segment;

FIG. 2 is a schematic structural view of a cross-pipe gallery section spliced from a plurality of pipe gallery sections;

FIG. 3 is an exploded view of a cross-pipe lane segment;

fig. 4 is a plan view of a prefabricated formwork manufactured by the method for manufacturing a vertical prefabricated formwork of an underground utility tunnel according to the present invention;

FIG. 4a is a view from the P-P direction in FIG. 4;

fig. 5 is a plan view of a bottom matrix manufactured when a bottom matrix manufacturing process of a bottom matrix manufacturing step is performed in the method for manufacturing a vertical prefabricated template for an underground utility tunnel according to the present invention;

FIG. 5a is a view from A-A in FIG. 5;

FIG. 5B is a view from the B-B direction in FIG. 5;

FIG. 5C is a view from the direction C-C in FIG. 5;

fig. 6 is a plan view of a primary impression mold fabricated when a primary impression mold fabrication process of a bottom mold fabrication step is performed in the method for fabricating a vertical prefabricated template for an underground utility tunnel according to the present invention;

FIG. 6a is a view from direction D-D in FIG. 6;

FIG. 6b is a view from E-E in FIG. 6;

FIG. 6c is a view from direction F-F of FIG. 6;

fig. 7 is a plan view of a secondary impression mold manufactured when the secondary impression mold manufacturing process of the bottom mold manufacturing step is performed in the method for manufacturing the vertical prefabricated formwork of the utility tunnel according to the present invention;

FIG. 7a is a view from the direction G-G in FIG. 7;

FIG. 7b is a view taken in the direction H-H of FIG. 7;

FIG. 7c is a view from direction I-I of FIG. 7;

fig. 8 is a plan view of a top mold fabricated when the top mold fabricating step is performed in the method for fabricating the vertical prefabricated formwork of the utility tunnel according to the present invention;

FIG. 8a is a view from direction J-J of FIG. 8;

FIG. 8b is a view from the K-K direction in FIG. 8;

FIG. 8c is an L-L view of FIG. 8;

fig. 9 is a plan view of an external mold fabricated while the external mold fabricating step is performed in the method for fabricating a vertical prefabricated formwork for an underground utility tunnel according to the present invention;

FIG. 9a is a view from direction M-M of FIG. 9;

fig. 10 is a plan view of the inner mold fabricated when the inner mold fabricating step is performed in the method for fabricating the vertical prefabricated formwork for the utility tunnel according to the present invention.

Detailed Description

The invention will be further explained with reference to the drawings.

Referring to fig. 1 to 10, in the method for manufacturing a vertical prefabricated formwork of an underground utility tunnel according to the present invention, the manufactured formwork is used for vertically prefabricating two-cabin type pipe gallery sections, each pipe gallery section has a top plate 100, a bottom plate 200, a left side plate 300, a partition wall 400 and a right side plate 500, and a corrugated pipe 600 is longitudinally pre-buried at each of four corners of each pipe gallery section. The plurality of pipe gallery sections are spliced into one-span pipe gallery section, and the multi-span pipe gallery section is spliced into the whole underground comprehensive pipe gallery through the cast-in-place section; each span of pipe gallery section comprises a head end pipe gallery section, a plurality of standard pipe gallery sections and a tail end pipe gallery section which are connected in sequence through shear connectors; the front end surface of the head end pipe gallery segment is provided with a concave shear key, and the rear end surface of the head end pipe gallery segment is a plane and exposes a reinforcing steel bar and a water stop steel plate which are used for being connected with the cast-in-place segment; a convex shear key matched with the shear key on the front end face of the head end pipe gallery section is arranged on the rear end face of each standard pipe gallery section, and a concave shear key is arranged on the front end face of each standard pipe gallery section; set up the protruding shear key that matches each other with the shear key on the preceding terminal surface of standard pipe gallery segment on the rear end face of terminal pipe gallery segment, the preceding terminal surface of terminal pipe gallery segment is the plane and exposes reinforcing bar and the stagnant water steel sheet that is used for linking to each other with cast-in-place section.

The vertical prefabricated formwork includes a bottom formwork 10, a top formwork 20, an outer formwork 30 and an inner formwork 40.

The invention discloses a method for manufacturing a vertical prefabricated template of an underground comprehensive pipe gallery.

Because the shear keys of the head end pipe gallery segment and the tail end pipe gallery segment in each span pipe gallery segment are opposite to each other, two types of bottom dies are arranged, and the difference is that the shear keys are in a concave-convex matching relationship; therefore, the bottom die 10 includes a first bottom die in which the shear keys on the bottom surface are concave when the pipe gallery segments are formed and a second bottom die in which the shear keys on the bottom surface are convex when the pipe gallery segments are formed; the second bottom die is used for prefabricating the head end pipe gallery section, and the formed shear key is concave; in order to meet the matching requirement of the joints between the pipe gallery sections, a stamping copying process is adopted, namely the three bottom dies are derived and copied from the same bottom die.

The bottom die manufacturing step sequentially comprises the following steps: bottom molding die making, primary impression making and secondary impression making.

In the bottom mold manufacturing process, the shear keys of the bottom mold 100A are recessed. Assembling a bottom matrix of a steel frame structure with the plane shape matched with the cross section shape of the pipe gallery on the leveling steel plate 80, wherein the bottom matrix comprises a top plate bottom matrix mould frame, a bottom plate bottom matrix mould frame, a left side plate bottom matrix mould frame, a partition wall bottom matrix mould frame and a right side plate bottom matrix mould frame; the partition wall bottom tire die frame comprises two partition wall main body channel steels which are vertically arranged oppositely, a plurality of partition wall transverse connection channel steels which are fixed between the two partition wall main body channel steels at intervals, and a partition wall steel plate strip which is fixed on the top surfaces of the two partition wall main body channel steels; the other bottom tire mold frames comprise bottom tire mold frame main bodies and a plurality of shear key boxes; the bottom die frame main body comprises two main body channel steels 11A which are vertically arranged oppositely, a plurality of transverse connection channel steels 12A which are fixed between the two main body channel steels 11A at intervals and a steel plate belt 13A which is fixed on the top surfaces of the two main body channel steels 11A, a plurality of box holes which are matched with the outer contour of the top of the shear key box are formed in the positions, corresponding to the shear keys, on the steel plate belt 13A, the shear key boxes 14A1 on the top plate bottom die frame and the bottom plate bottom die frame are rectangular, and the shear key boxes 14A2 on the left side plate bottom die frame and the right side plate bottom die frame are square; the plurality of shear key boxes are correspondingly arranged in the plurality of box holes one by one; four corners on the top surface of the bottom mold 100A are each provided with a circular hole 15A for fitting the magnet piece 16A at a position corresponding to the bellows 600.

When a primary impression making procedure is carried out, an impression process is adopted, a bottom matrix is leveled firstly, then a primary impression steel frame 1B is assembled on the top surface of the bottom matrix 100A, the planar shape and the size of the primary impression steel frame 1B are consistent with those of the bottom matrix 1A, and the primary impression steel frame comprises a top plate bottom mould frame, a bottom plate bottom mould frame, a left side plate bottom mould frame, a partition wall bottom mould frame and a right side plate bottom mould frame; all the bottom die frames comprise two main body channel steels 11B which are vertically arranged oppositely, a plurality of transverse connection reinforcing steel bars 12B which are fixed between the two main body channel steels 11B at intervals and steel plate belts 13B which are fixed on the bottom surfaces of the two main body channel steels 11B, and holes matched with the top profiles of the shear key boxes on the bottom forming dies 100A are formed in the steel plate belts 13B; then filling pouring concrete in the primary stamp die steel frame 1B and the shear key box, and compacting by vibration to form a primary stamp die 101A with a steel concrete structure with convex shear keys 14B1 and 14B 2; when concrete is filled, a round magnet piece 16B is respectively embedded in the four corners of the primary impression 101A corresponding to the positions of the corrugated pipe 600; the primary mold 101A is the first bottom mold.

When a secondary impression making procedure is carried out, an impression process is adopted, a primary impression 101A is turned by 180 degrees and placed on a leveling steel plate for leveling, then a secondary impression steel frame 1C is assembled on the top surface of the primary impression 101A, the making method of the secondary impression steel frame 1C is the same as the making method of the primary impression steel frame 1B, the planar shape and the size of the secondary impression steel frame 1C are the same as those of the primary impression steel frame 1B, and the secondary impression steel frame comprises a top plate bottom die set, a bottom plate bottom die set, a left side plate bottom die set, a partition wall bottom die set and a right side plate bottom die set; all the bottom die frames comprise two main body channel steels 11C which are vertically arranged oppositely, a plurality of transverse connection steel bars 12C which are fixed between the two main body channel steels 11C at intervals and a steel plate belt 13C which is fixed on the bottom surfaces of the two main body channel steels 11B, holes which are matched with the top profiles of the convex shear keys 14B1 and 14B2 on the primary die 101A are formed in the steel plate belt 13C, and a steel bar short material is arranged between the two main body channel steels 11C corresponding to each hole; pouring concrete is filled between the inside of the secondary stamp die steel frame 1C and the top surface of the primary stamp die 101A and is vibrated to be compact, and after molding, concave shear keys 14C1 and 14C2 are formed corresponding to the convex shear keys 14B1 and 14B2 on the primary stamp die 101A and become the secondary stamp die 102A with a steel concrete structure; when concrete is filled, a round magnet piece 16C is embedded in each of the four corners of the secondary impression 102A corresponding to the position of the corrugated pipe 600; the secondary die 102A is turned over and leveled to form a second bottom die.

The top die 20 also adopts the stamping process, namely a top die steel frame is assembled on the top surface of the bottom die 100A, the plane shape and the size of the top die steel frame are consistent with those of the bottom die 100A, and the top die steel frame comprises a top plate top die frame, a bottom plate top die frame, a left side plate top die frame, a partition wall top die frame and a right side plate top die frame; all top molds comprise two main bodies 21 and a plurality of transverse connections 22 connected between the two main bodies 21; each main body 21 and the transverse connection 22 are formed by welding two channel steels in a surrounding manner; a temporary support channel steel 23 is arranged between the bottom surface of each main body 21 and the top surface of the bottom moulding bed 100A; respectively placing a shear key cylinder 241 and 242 matched with the top contour of the shear key box on each shear key box 14A1 and 14B2 on the top plate top die frame, the bottom plate top die frame, the left side plate top die frame and the right side plate top die frame, and filling pouring concrete in each shear key cylinder 24 and 242 and the shear key boxes 14A1 and 14B2 and vibrating the concrete to be dense so that the concrete in each shear key cylinder and 242 is respectively consolidated with a transverse connection 22 into a whole; and limiting plates 25 are arranged on two sides of all the top die frames during concrete pouring.

When the outer mold manufacturing step is carried out, a top plate outer template, a bottom plate outer template, a left side plate outer template and a right side plate outer template which are all in a whole piece type are adopted, and all the outer templates comprise an L-shaped outer mold panel 31 with an arc-shaped corner, a plurality of horizontal ribs 32 fixed on the back of the outer mold panel 31 at consistent intervals and a plurality of vertical ribs 33 fixed on the horizontal ribs 32 at consistent intervals; the outer mold panel 31 is made of a steel plate with the thickness of 8mm, the horizontal ribs 32 are made of No. 8 channel steel, and the vertical ribs 33 are made of No. 18 channel steel; the outer side of the vertical rib 33 of each outer template is provided with an outer mold working platform 34 erected by square steel, and the joints of each outer template are spliced through diagonal draw bars 34 to form an outer mold 30.

When the internal mold manufacturing step is carried out, eight integral-piece internal mold plates which are L-shaped and have chamfered corners are adopted, namely a pair of left cabin top side internal mold plates 41, a pair of left cabin bottom side internal mold plates 42, a pair of right cabin top side internal mold plates 43 and a pair of right cabin bottom side internal mold plates 44; the pair of left cabin top side inner formworks 41 and the pair of left cabin bottom side inner formworks 42 are connected through the pin bolts 45 to form a pipe gallery left cabin inner mold; the pair of right cabin top side inner formworks 43 and the pair of right cabin bottom side inner formworks 44 are connected through the pin bolts 45 to form a pipe gallery right cabin inner mold; a hydraulic oil cylinder 46 is connected between the middle parts of the left cabin top side inner formworks 41 and the middle parts of the right cabin top side inner formworks 43; all of the inner formworks include an inner formwork panel 401, a plurality of horizontal ribs 402 secured at uniform intervals to the back of the inner formwork panel 401, and a plurality of vertical ribs 403 secured at uniform intervals to the horizontal ribs 402. The chamfering templates on the inner sides of the left cabin and the right cabin of the inner mold 4 are combined with the straight line template into a whole, and the chamfering templates are not arranged independently, so that the manufacturing process is simplified; the four inner templates in the left and right cabins are connected into a whole by using the pin bolts 45, and are freely folded by taking the pin bolts as axes under the control of a hydraulic system, so that the opening and closing of the inner side mold are completed.

When the prefabricated formwork assembling step is carried out, the outer formwork 30 is assembled, namely the top plate outer formwork and the left side plate outer formwork and the right side plate outer formwork as well as the bottom plate outer formwork and the left side plate outer formwork and the right side plate outer formwork are spliced and fastened through the 45-degree diagonal draw bars 35; and then, the outer die 30 is installed on the bottom die 10, namely, the bottom of the vertical rib 33 of each outer die plate is connected with the corresponding bottom die 10 through a diagonal draw bar 50, the inner die 40 is installed on the inner side of the outer bottom die 10, namely, the bottom of the vertical rib 43 of each inner die plate is connected with the corresponding bottom die 10 through a diagonal draw bar 50, then the top die 20 is hoisted and placed in place, namely, the top die 20 is placed between the top of the inner die 40 and the top of the outer die 30, the upper part of the vertical rib of each inner die plate is connected with the upper part of the vertical rib of the corresponding outer die plate through a brace 60 in a diagonal draw mode, so that the top of the inner die 40 and the top of the outer die 30 clamp the top die 20, and the elevation of the top die 20 is controlled through. When the pipe gallery segments are prefabricated, the bottom of the bottom die 10 needs to be leveled by the leveling steel plate 80.

According to the method for manufacturing the vertical prefabricated template of the underground comprehensive pipe gallery, the bottom die and the top die are manufactured by adopting the impression copying process, namely the bottom die with the concave shear key after molding, the bottom die with the convex shear key after molding, the top die with the concave shear key after molding and the top die with the convex shear key after molding are derived and copied from the same bottom moulding bed, so that the quality of all the bottom die and the top die can be well controlled, the manufactured prefabricated template has high precision, is suitable for large-scale prefabrication of large-section pipe gallery segments in factories, and is environment-friendly and economical.

The above embodiments are provided only for illustrating the present invention and not for limiting the present invention, and those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and therefore all equivalent technical solutions should also fall within the scope of the present invention, and should be defined by the claims.

Claims

1. A method for manufacturing a vertical prefabricated template of an underground comprehensive pipe gallery comprises the steps that the pipe gallery is formed by splicing a multi-span double-cabin pipe gallery, and each span of the double-cabin pipe gallery comprises a head-end pipe gallery section, a plurality of standard pipe gallery sections and a tail-end pipe gallery section which are sequentially connected through shear keys; the front end surface of the head end pipe gallery segment is provided with a concave shear key, and the rear end surface of the head end pipe gallery segment is a plane and exposes a reinforcing steel bar and a water stop steel plate which are used for being connected with the cast-in-place segment; a convex shear key matched with the shear key on the front end face of the head end pipe gallery section is arranged on the rear end face of each standard pipe gallery section, and a concave shear key is arranged on the front end face of each standard pipe gallery section; the rear end face of the tail end pipe gallery section is provided with a convex shear key matched with the shear key on the front end face of the standard pipe gallery section, and the front end face of the tail end pipe gallery section is a plane and is exposed with a steel bar and a water stop steel plate which are used for being connected with the cast-in-place section; all the pipe gallery sections comprise bottom plates, top plates, left side plates, partition walls and right side plates; the manufacturing method of the prefabricated template comprises a bottom die manufacturing step, a top die manufacturing step, an outer die manufacturing step, an inner die manufacturing step and a template assembling step; it is characterized in that the preparation method is characterized in that,

2. The method for manufacturing the vertical prefabricated template of the underground comprehensive pipe gallery according to claim 1, wherein a working platform made of square steel is connected to the outer side surfaces of all the outer templates.

3. The manufacturing method of the vertical prefabricated formwork of the underground comprehensive pipe gallery according to claim 1, wherein the outer die panels and the inner die panels are made of steel plates with the thickness of 8mm, the horizontal ribs are made of 8-size channel steel, and the vertical ribs are made of 18-size channel steel.