CN112726438A - Multifunctional movable box-type internal mold, manufacturing method thereof and box culvert pouring method - Google Patents

Abstract

The invention discloses a multifunctional movable box type internal mold and a manufacturing method and a pouring method thereof, wherein the internal mold comprises a support rod piece, a structural rib, an internal mold steel plate and a hydraulic rod piece, the support rod piece is formed by mutually welding a flat rod, a vertical rod and an inclined rod, the structural rib is arranged on the support rod piece, the internal mold steel plate is arranged on the outer surface of the structural rib, the internal mold steel plate is formed by punching a whole steel plate and is n-shaped, and the lower end of the internal mold steel plate can be tightly attached to a side wall which is poured at one time; the corner of the structural rib is broken to form a hinge point, the movable section of the structural rib below the hinge point is connected with the hydraulic rod piece, and the movable section can be driven to rotate by the extension and retraction of the hydraulic rod piece, so that the vertical section of the inner die can be removed and closed. The folding type internal mold is reasonable in design, light and handy in structure, convenient to use, multiple in purpose, high in accuracy, convenient to operate and easy to popularize and implement, and the internal mold can be folded for installation and disassembly.

Description

Multifunctional movable box-type internal mold, manufacturing method thereof and box culvert pouring method

The technical field is as follows:

the invention relates to a civil engineering technology, in particular to a multifunctional movable box type internal mold and a manufacturing and box culvert pouring method thereof.

Background art:

with the adoption of box-type structures commonly used in culverts and channels of highways, construction modes are divided into an assembly type and a cast-in-place type, and a folding internal mold becomes a preferred scheme for cast-in-place construction.

The folding internal mold has the characteristics of mature technology, stable structure, shaping manufacture, convenient assembly and disassembly and the like.

However, through long-term construction practice, the common folding internal mold has some defects and needs to be improved.

Firstly, when using integral folding centre form monolithic casting, will take to open a hole at the bottom plate or hang the bottom plate earlier, pour bottom plate concrete, fall the bottom plate again, with the method of curb plate connection, the bottom plate is difficult to with concrete surface laminating completely, and has higher requirements for concrete performance, the centre form shifts out the degree of difficulty greatly, and folding position seam is many, and the outward appearance effect is unsatisfactory.

Secondly, when the upper segment and the lower segment are separately poured by using the sectional type folding internal mold, the internal mold needs to be erected on a poured bottom plate, the difficulty in accurate positioning is high, and the main problems are that the number of the produced construction joints and the number of the splicing joints at the folding position are large, and the appearance effect is also poor.

The invention content is as follows:

the technical problem to be solved by the invention is as follows: overcomes the defects of the prior art, and provides a multifunctional movable box type internal mold which has reasonable design, light structure, convenient use and various purposes and a manufacturing method thereof.

The technical scheme of the invention is as follows:

a multifunctional movable box type internal mold comprises a support rod piece, a structural rib, an internal mold steel plate and a hydraulic rod piece, wherein the support rod piece is formed by mutually welding a flat rod, a vertical rod and an inclined rod, the structural rib is arranged on the support rod piece, the internal mold steel plate is arranged on the outer surface of the structural rib, the internal mold steel plate is formed by punching a whole steel plate and is in an inverted U shape, and the lower end of the internal mold steel plate can be tightly attached to a side wall which is poured at one time; the corner of the structural rib is broken to form a hinge point, the movable section of the structural rib below the hinge point is connected with the hydraulic rod piece, and the movable section can be driven to rotate by the extension and retraction of the hydraulic rod piece, so that the vertical section of the inner die can be removed and closed.

The hinge points are two and are respectively positioned at the lower left part and the lower right part of the construction rib. The lower extreme interval of support member is provided with the walking wheel, be provided with the reaction frame on the support member, the reaction frame with the one end of hydraulic rod spare is connected.

Support ribs are arranged on the upper end flat rod of the support rod piece at intervals, reinforcing ribs are arranged on the support ribs, the reinforcing ribs are provided with the construction ribs, and the shapes of the reinforcing ribs are matched with those of the construction ribs.

The manufacturing method of the multifunctional movable box-type inner mold comprises the following steps:

a. manufacturing the support rod piece:

selecting section steel with proper specification to be blanked according to design requirements, adopting angle steel or square steel, selecting double angle steel or I-shaped steel for a bottom supporting flat bar according to the bearing capacity, respectively welding a flat bar, an upright bar and an inclined bar on the side surface, wherein the longitudinal length of a supporting frame is slightly shorter than that of an inner mold, each end is 0.1m shorter, selecting a flat ground when welding, or welding a transverse flat bar, an upright bar and an inclined bar on a special platform to form a frame of the supporting frame, and each section is provided with three supporting cross sections;

b. the manufacturing of the inner die steel plate comprises the following steps:

selecting a whole steel plate for blanking, and stamping according to the design size to form an inverted U-shaped section;

c. manufacturing the structural rib:

selecting angle steel or strip steel with proper specification, welding latticed structural ribs on a flat working surface, wherein the top surface is provided with corners and two side surfaces are respectively welded to form three blocks, and each corner part is provided with two hinge points, namely rotating points, so that the three structural ribs are connected into a whole;

three reinforcing ribs are arranged at two ends and the middle section, the ribs are in the same structure in a transverse subsection mode, square steel welding is carried out, the reinforcing ribs are used for connecting and detaching hydraulic rods on the side face of the inner die and dispersing the supporting weight on the ribs, the deformation of a steel plate is reduced, if the supporting weight is smaller, the manufacturing of the ribs is accurate, and the reinforcing ribs can be omitted;

d. the hydraulic rod piece is installed:

selecting a proper position to install a hydraulic rod piece, arranging four hydraulic rods in each section of internal mold, fixing one end of each hydraulic rod on a vertical rod, connecting the other end of each hydraulic rod on vertical structural ribs or reinforcing ribs on two sides, and arranging hinge joints at two fixed ends;

e. mounting a traveling wheel:

selecting a horizontal and solid ground, placing the top surface of the frame of the support rod piece on the ground, determining the height of the bottom walking wheels according to the designed lifting range of the internal mold, accurately positioning and leveling the ground during installation, and setting the integral lifting height to be 0.1 m;

f. integral adjustment:

adjusting a hydraulic rod to enable the positions of the net ribs on the two sides to reach the designed cross surface size, fixing the hydraulic rod, jacking the whole support by a jack and a support leg, enabling the travelling wheel to be separated from the ground and accurately leveled, lifting a stamped internal mold steel plate in place, using auxiliary measures to tightly attach the steel plate to each part of the net rib, locally performing spot welding, checking the section size and the flatness, welding the steel plate and the net rib from inside to outside one by one, adopting interval operation, avoiding centralized welding and reducing the thermal deformation of the steel plate.

The walking wheel is contacted with the ground, a supporting rib is arranged according to the designed position and is welded or connected with the top end of the bracket through a bolt; and (3) lapping the horizontal latticed structural ribs of the inner die on the supporting ribs on the top surface of the bracket, accurately adjusting the positions, fixing the reinforcing ribs and the structural ribs by spot welding, and accurately leveling in the welding process.

The supporting rod piece is integrally supported by a jack, the travelling wheel is suspended, the movable supporting leg is used for supporting and leveling, and the hydraulic rod is adjusted, so that the cross section of the internal mold conforms to the design size; and installing an end die, fixedly connecting the end die with the inner die, and then installing a side die, and fixedly connecting the side die with the side surface of the end die.

The method for manufacturing the internal mold of the prefabricated box culvert segment comprises the following steps:

a. the cast-in-place box culvert segment internal mold can be moved to a prefabricating field and used for horizontal segmental prefabrication of assembly type box culvert segments, the upper and lower segments of the segments are produced in an n-shaped position, the upper segment is still installed in the n-shaped position, and the lower segment is installed in the u-shaped position after being overturned by 180 degrees;

b. basic construction and manufacturing method of the segment internal mold;

(1) the inner die is fixed on a base welded by section steel, the length of the inner die is designed length, the end die and the side die are integrally arranged on a pair of trapezoidal inclined struts, and travelling wheels are arranged at the lower ends of the inclined struts and supported on longitudinal beams and transverse beams of the base;

(2) the corner part of the internal mold can be provided with hinged joints only at the upper left and upper right turning points, and the hydraulic rod is arranged as the same as the above;

(3) the bottom of the segment is provided with a socket bottom plate, the top of the segment is provided with a socket and a flat top plate, the socket bottom plate is arranged on longitudinal and transverse supporting beams of the base, and the socket top plate at the top is fixed on the side plates and the end plates;

(4) the movement of the end plate and the side plate is realized by the expansion of a hydraulic rod connected with the inclined strut and the reaction frame;

(5) the same unit is used for ensuring smooth butt joint of the bearing and the socket when the segments are installed; the socket and spigot templates are produced on the same equipment, so that the segments are well matched during prefabrication, and the visual effect of installation is improved;

(6) the template for segment prefabrication is installed and debugged as before.

A box culvert pouring method using the multifunctional movable box type internal mold comprises the following steps:

A. construction of cast-in-place box type sections:

(1) pouring the segmental floor and part of the wall:

the bottom plate and part of the side wall steel bars are manufactured and installed on site, the bottom plate and part of the side wall steel bars correspond to a lofting position, then the side mold and the end mold are erected, or the part of the end mold and the side mold are poured in an erected mode after lofting, then the steel bars are installed, the side wall vertical steel bars with full sections are completed during installation, lap joint sections are not arranged as far as possible, and the phenomenon that concrete slump is influenced by excessive density of the steel bars is avoided;

when pouring, paving and compacting the concrete of the bottom plate part at intervals, pouring the concrete of the side wall part on the basis that the concrete of the bottom plate does not flow under the pressure and vibration of the concrete of the side wall, and controlling the flatness, the cross section and the longitudinal dimension of the bottom plate to correspond to the dimension of the internal mold, the straightness of the template of the side wall part and the top elevation during pouring;

(2) pouring a top plate and the residual side walls:

after the bottom plate and the lower side wall are demolded, the whole of the multifunctional movable box-type internal mold is pulled to a design position and is accurately aligned, the internal mold is integrally jacked up, a jack is adjusted, the templates on two sides are tightly attached to the inner side of the poured side wall, the end mold is tightly attached to the end part of the poured bottom plate, the section size is checked, the adjustment is carried out through movement and lifting, then the side plate and the end plate of the internal mold are loosened, the steel bar is installed or the steel bar is installed firstly and then the template is combined, after the installation is finished, the side plate and the end plate are combined, an attached vibrator is additionally hung, and the side mold, the size; pouring and vibrating concrete layer by layer, and covering the top surface for curing;

the mold stripping sequence is as follows: firstly, loosening the connection between the segment end die and the side die and between the end die and the internal die steel plate, dismantling the side die, removing the end plates, adjusting the jacks, collecting a small amount of the two side plates and the corners to separate the two side plates and the corners from the surface of concrete, placing the jacks on the ground at the lower ends of the flat rods at the lower parts of the two ends of the support, adjusting and lifting the jacks to be tightly propped against the lower ends of the flat rods, adjusting lead screws of the support legs to fall, moving the support legs out, and adjusting the jacks to enable the support to fall slowly; the walking wheels are contacted with the bottom plate, the jack is moved out, and then the inner mold is integrally pulled out;

b. and (3) space segment cast-in-place construction:

the construction method is the same as the construction method, so that the construction of the upper part of the section is continuously carried out, when the construction is arranged, the bottom plate and part of the side wall part can be continuously poured in sequence, and the top plate and the rest of the side wall part are constructed by adopting a 'skip method';

c. and (3) middle section cast-in-place construction:

(1) firstly, installing reinforcing steel bars of the side wall of the middle section, detaching an end plate of the inner mold, simultaneously partially retracting the side wall of the inner mold through adjusting a hydraulic rod, integrally pulling the inner mold to the position of the middle section, respectively extending the lap joint sections at two ends of the inner mold into the two poured sections in proper amount and centering, placing a jack between a bottom flat rod and the ground, jacking the inner mold integrally, and tightly attaching two ends to the lower end of the top plate of the poured section;

(2) adjusting a hydraulic rod, jacking the wall parts on the two sides of the inner mold, tightly attaching the inner sides of the cast section side walls, arranging seams and settlement seams, hanging a vibrator, installing top plate steel bars and embedded parts after the side mold is in place and supported stably, and casting concrete;

(3) when the formwork is disassembled, the outer formwork is removed, the hydraulic rod is adjusted to enable the inner formwork side plate to contract inwards a little to be separated from the concrete surface, finally the jack at the lower end is tightly jacked, the supporting leg screw rod is adjusted to enable the supporting leg screw rod to be separated from the support and move out, the jack is loosened to enable the travelling wheel to contact the ground, meanwhile, the inner formwork top plate is separated from the concrete surface, and then the inner formwork is integrally pulled to the next working surface.

Horizontal sectional construction of assembled box culvert sections:

(1) template preparation:

polishing the bottom plate, the inner mold and the side mold on the pedestal, removing dust and rust, brushing a release agent on the pedestal to enable the large surface to be smooth and flat, and adjusting a hydraulic rod to enable the inner mold to be in place and fixed firstly;

(2) manufacturing a segmental integral reinforcement cage on a special high-precision formwork, wherein the reinforcement cage can be manufactured by a segmental internal mold supporting frame, and on the basis of an original structure, a positioning toothed plate and a supporting short rib are arranged on a support according to a segmental design drawing, and a lifting appliance is manufactured according to a framework structure;

(3) after the framework is formed and tested, a lifting tool is used for lifting a framework lifting point, force is slowly applied to separate the framework lifting point from a mold frame, the lifting process is kept at a constant speed and slowly moves, the collision of an inner mold is avoided when the framework is put into the mold, the condition of a protective layer is checked after the framework is in place, deviation is corrected, and the missing cushion blocks are complemented; starting a hydraulic rod, closing and fastening the 2 end molds and the 2 side molds, processing seams, and hanging a vibrator;

(4) checking the whole size and the sealing condition after die assembly, installing embedded parts, and pouring concrete in the preformed hole in a layered mode and maintaining;

(5) after the concrete reaches the designed form removal strength, respectively loosening the fasteners and the connecting bolts between the side form and the end form, starting the jack, and respectively pulling out the side form and the end form; starting a jack on the internal mold supporting frame, pulling the internal side template of the side mold inwards to separate the internal side template from the surface of the concrete, and simultaneously separating the corner part from the concrete;

(6) hanging a hanging ring arranged on the top surface by using a special lifting appliance (the upper section of the segment is prefabricated in an inverted U-shaped position, and the top surface is provided with the hanging ring) or reserving a hanging hole on the side surface, and lifting and moving to a storage site;

for the lower section prefabricated by the U-shaped body position, a reserved hoisting hole is formed in the side surface, and the lower section is hoisted to the turnover frame by a special hoisting tool during hoisting, turned over for 180 degrees, changed into the U-shaped installation position and then hoisted to a storage site.

The invention has the beneficial effects that:

1. the materials and equipment required by the invention are shaped products, so the invention has the advantages of easy purchase or processing, light structure, quick construction and higher precision. In addition, the walking wheels are installed at the bottom of the box type internal mold supporting frame, supporting legs and jacks are matched for lifting and descending, the top plate template is conveniently and quickly detached, and the box type internal mold supporting frame is convenient to pull.

2. The inner die steel plate designed by the invention is manufactured by integral punching, is welded on the reticular rib in an attaching way, and is provided with a reinforcing rib at two ends (and the middle). The side surface of the inner die is connected with a hydraulic rod, so that the deformation of the side plate during opening and closing is reduced, and no supporting rib is arranged at the top of the supporting frame, so that the integral rigidity of the inner die top plate is increased, the moving range of a rotating point of a corner part can be increased, and the side plate can be conveniently retracted.

3. The structural net rib designed by the invention is provided with a turning point at each turning position, two adjacent net ribs at the turning points are disconnected and form wedge-shaped openings, the reinforcing ribs are connected with each other through a hinge joint, when the hydraulic rod drives the side plate to retract or extend outwards, the joint of the wedge-shaped openings and the steel plate only generates small deformation, and the joint can be separated from the surface of concrete, and the compressive fatigue strength of the steel plate can meet the requirements of installation, disassembly and turnover of the internal mold within the service life.

4. The cast-in-place segment sectional construction designed by the invention has the advantages that the bottom plate and part of the side wall are continuously cast in place (cast to a proper height above the corner), and then the upper section is cast at intervals (a skip method), so that the precise alignment and movement of the internal mold are facilitated, and the working efficiency is improved.

5. The longitudinal length of the segmental internal mold designed by the invention is larger than the designed length by a proper amount, so that when the segmental sequential casting or the skip method casting is carried out on the internal mold, one end or two ends of the segmental internal mold extend into the cast segmental, and the template is tightly attached to the inner wall of the segmental internal mold through the adjustment of the hydraulic rod, thereby being beneficial to ensuring the smooth linear shape, flattening the joint and improving the appearance effect.

6. The segmental bottom plate and partial side walls are poured in advance, construction is relatively easy, the appearance quality of the bottom plate is improved, when the upper section is poured, the inverted U-shaped section is free of redundant abutted seams and only 2 construction seams exist with the lower section side walls, and the appearance effect is easy to guarantee.

7. When the internal mold is used for horizontal segmental construction of the assembled box culvert segment, the internal mold supporting structure can be basically and completely reserved, only the base is arranged on the ground, the internal mold travelling wheels are detached, and the hydraulic rod supporting point, namely the reaction frame, is arranged at a proper position.

8. The side mould and the end mould of the prefabricated segment can transform the side mould end originally used for cast-in-place construction, weld the net rib of the whole template on two trapezoidal inclined struts, and install the travelling wheels at the bottoms of the inclined struts and support the travelling wheels on the longitudinal beams and the transverse beams of the base. Each inclined strut is provided with a hydraulic rod which is supported on the inclined strut and a reaction frame arranged at a proper position on the longitudinal beam and the transverse beam, and the template is driven by the extension and contraction of the hydraulic rod to move so as to realize opening and closing. The improved horizontal full-hydraulic support template can be operated by only 1-2 persons, and is convenient and efficient to mount and dismount.

9. The invention relates to a method for arranging an upper section interface and a lower section interface-rabbet of a horizontal sectional prefabricated template.

10. The horizontal bearing and socket templates of the same unit (such as 3 complete segments assembled into one segment) are also manufactured in the same equipment and are matched and prefabricated with the upper segment and the lower segment together, so that the joint in the horizontal direction and the vertical direction can be ensured to be smooth after installation, and the appearance effect is good.

11. The folding inner die has the advantages of reasonable design, light and handy structure, convenience in use, multiple purposes, high accuracy, convenience in operation, easiness in popularization and implementation and better economic benefit, and the inner die can be folded for installation and disassembly.

Description of the drawings:

FIG. 1 is a schematic view of a transverse structure of a multifunctional mobile box-type inner mold;

FIG. 2 is a side view of the multifunctional movable box-type inner mold shown in FIG. 1;

FIG. 3 is a transverse structural diagram of the multifunctional movable box-type internal mold for horizontal prefabrication of a box culvert in sections;

fig. 4 is a top view structural diagram of the box culvert sectional horizontal type prefabricated structure shown in fig. 3.

The specific implementation mode is as follows:

example (b): referring to fig. 1-4, in the drawings, 1-limiting plate, 2-side mold support, 3-side mold, 4-fence, 5-end plate, 6-structural rib, 7-reinforcing rib, 8-supporting rod piece, 9-supporting rib, 10-hinge point, 11-primary pouring part, 12-foundation, 13-hydraulic rod, 14-connecting rod, 15-supporting rod piece walking wheel, 16-jack, 17-movable supporting leg, 18-secondary pouring part, 19-reaction frame, 20-jack, 21-base longitudinal beam, 22-socket bottom plate, 23-base cross beam, 24-side mold walking wheel and 25-preformed hole.

Manufacturing method for cast-in-situ box culvert segment internal mold

1. Manufacturing the support rod 8:

as shown in fig. 1 and 2, the section steel with a suitable specification is selected according to the design requirement, angle steel and square steel can be adopted, and the bottom support flat rod (a flat rod supported on a supporting leg or the ground) can be double angle steel or I-shaped steel according to the bearing capacity. And respectively welding a flat rod, a vertical rod and an inclined rod on the side surface, wherein the longitudinal length of the support frame is slightly shorter than that of the inner mold (each end is 0.1m shorter), and one flat ground is selected during welding or is carried out on a special platform.

And welding the horizontal flat rod, the vertical rod and the inclined rod to form a frame of the support frame. Each section is provided with three supporting cross sections.

2. Welding inner die steel plate mesh ribs:

as shown in figure 1, a whole steel plate is selected for blanking, and the steel plate is punched according to the designed size to form a n-shaped section.

Selecting section steel (angle steel or strip steel) with proper specification, welding latticed structural ribs 6 (three structural ribs are respectively welded on the top surface, the corner and the two side surfaces, and the total number of the structural ribs is three), arranging two hinge points, namely 'turning points 10', at each corner part, and connecting the three structural ribs into a whole.

Three reinforcing ribs 7 are arranged at two ends and the middle section, the ribs are in the same structure in a transverse subsection mode, square steel welding is conducted, the reinforcing ribs are used for connecting and detaching hydraulic rods on the side face of the inner die and dispersing the supporting weight on the ribs 6, deformation of a steel plate is reduced, if the supporting weight is small, the ribs 6 are accurately manufactured, and the reinforcing ribs 7 are not needed.

1. Assembling the inner die segments:

as shown in fig. 1 and 2:

(1) selecting a horizontal and firm ground, placing the top surface of the frame of the support formed by the support rod pieces 8 on the ground, determining the height of the walking wheels 15 on the bottom surface (the top surface at this time) according to the designed lifting range of the internal mold, accurately positioning and leveling the ground during installation, and considering the whole lifting height to be 0.1 m.

(2) Turning the support, enabling the walking wheels 15 to contact the ground, installing the supporting ribs 9 according to the designed positions, and connecting the supporting ribs with the top end of the support through welding or bolts.

(3) Lapping horizontal latticed construction ribs (hereinafter referred to as net ribs) of the inner die on the supporting ribs on the top surface of the bracket, accurately adjusting the positions, fixing the reinforcing ribs 7 and the construction ribs 6 by spot welding, and accurately leveling in the welding process.

(4) Connecting the vertical construction ribs with the horizontal construction ribs of the top surface, respectively, by turning points (hinge points).

(5) Selecting proper position to install hydraulic rod 13, and setting four hydraulic rods 13 in each section. One end of the hydraulic rod 13 is fixed on the vertical rods at the two ends of the bracket, the other end is connected on the vertical structural ribs 6 or the reinforcing ribs 7 at the two sides, and the two fixed ends are provided with hinged joints.

(6) Adjusting a hydraulic rod 13 to enable the positions of the net ribs on the two sides to reach the designed cross-face size, fixing the hydraulic rod 13, jacking the whole support by a jack 16 and a movable supporting leg 17, enabling a walking wheel 15 to be separated from the ground and accurately leveled, hoisting a stamped internal mold steel plate in place, using auxiliary measures, attaching the steel plate to each part of the net rib tightly, performing local spot welding, checking the section size and the flatness, welding the steel plate and the net rib from inside to outside one by one, adopting interval operation, avoiding centralized welding and reducing the thermal deformation of the steel plate.

4. Manufacturing an end die 5:

as shown in figure 1, the end die steel plate is made of a whole steel plate, structural ribs are arranged on the outer side of the steel plate, bolt holes are arranged at the contact parts of the end die steel plate and the inner die and the side die, and the end die steel plate and the bolt holes at the corresponding positions on the inner die and the side die are fixedly connected through bolts.

5. Manufacturing a side die 3:

as shown in fig. 1, the side-die steel plate is welded to the structural rib of the side-die holder 2, and the rail 4 is provided on the top of the holder. When the side die 3 is fixed, bolt holes are arranged at the contact positions of the inner side of the end part of the side die with the end die 5 and the inner die and are connected through bolts, and the middle part of the side die is fixed with the inner die through a pull rod bolt. Angle steel can also be arranged on the ground or the foundation on the outer side to be used as the limit plate 1, and the inclined strut is properly arranged for fixation.

6. Integrally installing and adjusting the template:

as shown in fig. 1, the internal mold is firstly supported by a jack, the travelling wheels are suspended, the internal mold is supported and leveled by the supporting legs, and the hydraulic rod of the internal mold is adjusted to make the cross section of the internal mold accord with the design size. And installing an end die, fixedly connecting the end die with the inner die, and then installing a side die, and fixedly connecting the side die with the side surface of the end die.

Checking the sizes and sealing conditions of all directions and all parts after the template is installed, adjusting errors, welding steel plates and mesh ribs after the template is qualified, arranging an attached vibrator external hanging point at the proper part of the mesh ribs outside the side die and on the side surface of the inner die, installing a vibrator, simulating vibration, checking whether the inner template and the outer template are loosened or not, shifting, supporting and stabilizing or not again, and correcting deviation in time. And removing the side plates and the end plates, retracting a little of the two side molds (simulating mold removal), putting down the supporting legs, pulling the segments to move integrally, and checking the stable condition.

Secondly, manufacturing of the prefabricated box culvert segment internal molds:

1. the cast-in-situ box culvert segment internal mold can be moved to a prefabricating field and used for horizontal segmental prefabrication of the assembly type box culvert segments. The upper and lower segments of the segment are produced in reverse U-shaped position, the upper segment is still installed in reverse U-shaped position, and the lower segment is installed in reverse U-shaped position after being turned over 180 deg. As shown in fig. 3 and 4.

2. The basic structure and the manufacturing method of the segment internal mold are the same as those of the segment internal mold.

(1) The centre form is fixed on the base that the shaped steel welded, and centre form length is design length, and end mould, side form integral erection are on a pair of trapezoidal bracing, and the walking wheel is installed to the bracing lower extreme, and the supporting is on base longeron 21 and base crossbeam 23.

(2) The inner mold corner part can be provided with hinged points only at the upper left and upper right rotating points, and the hydraulic rod is arranged as before.

(3) The bottom of the segment is provided with a socket bottom plate 20, the top is provided with a socket and a flat top plate, the socket bottom plate is arranged on the longitudinal and transverse supporting beams of the base, and the socket top plate at the top is fixed on the side plates and the end plates.

(4) The movement of the end plates and side plates is effected by means of the extension and retraction of hydraulic rods 20 connected to the diagonal braces and the reaction frame 19 (provided on the base longitudinal beams 21 and the base transverse beams 23).

(5) In order to ensure smooth butt joint of the bearing and the socket during installation of the segments, the bearing and socket templates of the same unit (for example, 3 segments are an installation unit) are produced on the same equipment, so that the segments are well matched during prefabrication, and the visual effect of installation is improved.

(6) The template for segment prefabrication is installed and debugged as before.

Thirdly, the using method comprises the following steps:

1. construction of cast-in-place box type sections:

(1) pouring the segmental floor and part of the wall:

the method comprises the steps of on-site manufacturing, installing bottom plate and partial side wall reinforcing steel bars, corresponding to a lofting position, erecting side molds and end molds, or erecting end molds and side molds of a pouring part after lofting, installing the reinforcing steel bars, completing the full-section side wall vertical reinforcing steel bars during installation, and avoiding influence on concrete slump due to over-dense reinforcing steel bars due to the fact that lap joint sections are not arranged as far as possible.

When pouring, the bottom plate part concrete is fully paved and compacted, the side wall part concrete is poured at intervals (based on the condition that the bottom plate concrete does not flow under the pressure and vibration of the side wall concrete), and the flatness, the cross section and the longitudinal dimension of the bottom plate are controlled to correspond to the dimension of the internal mold, and the straightness and the top elevation of the side wall part template are controlled during pouring.

(2) Pouring a top plate and the residual side walls:

and after the bottom plate and the lower side wall are demolded, integrally pulling the inner mold to a designed position and accurately aligning. The integral internal mold is jacked up firstly, the jack is adjusted to enable the templates on two sides to be attached to the inner side of a poured side wall, the end mold is attached to the end part of a poured bottom plate, the section size is checked, the side plate and the end plate of the internal mold are adjusted through moving and lifting, then the side plate and the end plate of the internal mold are loosened, the reinforcing steel bar begins to be installed (the reinforcing steel bar can be installed firstly and then the template is closed), after the installation is finished, the side plate and the end plate are closed, the attached vibrator is hung additionally, and the side mold.

Pouring and vibrating the concrete layer by layer, and covering the top surface for curing.

The mold stripping sequence is as follows: firstly, loosening the connection between the segment end mould and the side mould and between the end mould and the internal mould steel plate, dismantling the side mould, removing the end plate, adjusting the jack, collecting a little of the two side plates and the corner to separate the two side plates and the corner from the concrete surface, placing the jack on the ground at the lower end of the flat rod at the lower part of the two ends of the support, adjusting and lifting the jack to be tightly propped against the lower end of the flat rod, adjusting the lead screw of the support leg to fall, moving the support leg out, adjusting the jack to enable the support to fall slowly. The walking wheels are contacted with the bottom plate, the jack is moved out, and then the inner mold is integrally pulled out.

2. And (3) space segment cast-in-place construction:

as with the construction method, in order to continuously carry out the construction of the upper part of the segment, the bottom plate and part of the side wall parts can be continuously poured in sequence during the construction arrangement, and the top plate and the rest of the side wall parts are constructed by adopting a 'skip method'.

3. And (3) middle section cast-in-place construction:

(1) firstly installing the reinforcing steel bars of the middle section side wall, detaching the inner mold end plate, simultaneously packing up the inner mold side wall part through the adjusting hydraulic rod, integrally pulling the inner mold to the middle section position, respectively extending the lap joint sections at the two ends of the inner mold into two sections which are poured in proper amount and centered, placing a jack between the bottom flat rod and the ground, integrally jacking the inner mold, and tightly attaching the two ends to the lower end of the poured section top plate.

(2) Adjusting a hydraulic rod, jacking the wall parts on the two sides of the inner die, tightly attaching the wall parts to the inner sides of the poured segmental side walls, arranging seams and settlement joints, hanging a vibrator, installing top plate steel bars and embedded parts after the side die is in place and supported stably, and pouring concrete.

(3) When the formwork is disassembled, the outer formwork is removed, the hydraulic rod is adjusted to enable the inner formwork side plate to contract inwards a little to be separated from the concrete surface, finally the jack at the lower end is tightly jacked, the supporting leg screw rod is adjusted to enable the supporting leg screw rod to be separated from the support and move out, the jack is loosened to enable the travelling wheel to contact the ground, meanwhile, the inner formwork top plate is separated from the concrete surface, and then the inner formwork is integrally pulled to the next working surface.

4. Horizontal sectional construction of assembled box culvert sections:

(1) template preparation:

and (3) polishing the bottom plate, the inner mold and the side mold on the pedestal, removing dust and rust, brushing a release agent on the pedestal to enable the large surface to be smooth and flat, and adjusting a hydraulic rod to enable the inner mold to be in place and fixed firstly.

(2) And manufacturing the segment integral reinforcement cage on the special high-precision formwork. The reinforcing steel bar formwork can be made of a segmental internal formwork supporting frame. On the basis of the original structure, according to a section design drawing, a positioning toothed plate and a supporting short rib are arranged on a support, and a lifting appliance is manufactured according to a framework structure.

(3) After the framework is formed and tested, a lifting tool is used for lifting a framework lifting point, force is slowly applied to separate the framework lifting point from a mold frame, the lifting process is kept at a constant speed and slowly moves, the collision of an inner mold is avoided when the framework is placed in the mold, the condition of a protective layer is checked after the framework is in place, deviation is corrected, and the missing cushion blocks are complemented.

And (3) starting a hydraulic rod, closing and fastening the 2 end dies and the 2 side dies, processing the joint, and hanging a vibrator.

(4) Checking the whole size and the sealing condition after die assembly, installing embedded parts, and pouring concrete in the preformed hole in a layered mode and maintaining.

(5) After the concrete reaches the designed form removal strength, the fasteners and the connecting bolts between the side forms and the end forms are respectively loosened, and the jacks are started to respectively pull out the side forms and the end forms. And starting a jack on the internal mold supporting frame, pulling the internal side template of the side mold inwards to separate the internal side template from the surface of the concrete, and simultaneously separating the corner part from the concrete.

(6) Hanging the hanging rings arranged on the top surface by a special lifting appliance (the upper sections of the segments are prefabricated in inverted U-shaped positions, the hanging rings are arranged on the top surface) or the reserved lifting holes on the side surfaces, and lifting and moving to a storage site.

For the lower section prefabricated by the U-shaped body position, a reserved hoisting hole is formed in the side surface, and the lower section is hoisted to the turnover frame by a special hoisting tool during hoisting, turned over for 180 degrees, changed into the U-shaped installation position and then hoisted to a storage site.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and all simple modifications, equivalent variations and modifications made to the above embodiment according to the technical spirit of the present invention still fall within the scope of the technical solution of the present invention.

Claims (10)

1. The utility model provides a multi-functional portable box centre form, includes support member, structure rib, centre form steel sheet and hydraulic pressure member, characterized by: the support rod piece is formed by mutually welding a flat rod, a vertical rod and an inclined rod, the support rod piece is provided with the structural rib, the outer surface of the structural rib is provided with the inner die steel plate, the inner die steel plate is formed by stamping a whole steel plate and is n-shaped, and the lower end of the inner die steel plate can be tightly attached to a side wall which is poured at one time; the corner of the structural rib is broken to form a hinge point, the movable section of the structural rib below the hinge point is connected with the hydraulic rod piece, and the movable section can be driven to rotate by the extension and retraction of the hydraulic rod piece, so that the vertical section of the inner die can be removed and closed.

2. The multifunctional mobile box type internal mold according to claim 1, wherein: the hinge points are two and are respectively positioned at the lower left part and the lower right part of the construction rib.

3. The multifunctional mobile box type internal mold according to claim 1, wherein: the lower extreme interval of support member is provided with the walking wheel, be provided with the reaction frame on the support member, the reaction frame with the one end of hydraulic rod spare is connected.

4. The multifunctional mobile box type internal mold according to claim 1, wherein: support ribs are arranged on the upper end flat rod of the support rod piece at intervals, reinforcing ribs are arranged on the support ribs, the reinforcing ribs are provided with the construction ribs, and the shapes of the reinforcing ribs are matched with those of the construction ribs.

5. A method for manufacturing the multifunctional movable box type inner mold as claimed in any one of claims 1 to 4, comprising the following steps:

a. manufacturing the support rod piece:

selecting section steel with proper specification to be blanked according to design requirements, adopting angle steel or square steel, selecting double angle steel or I-shaped steel for a bottom supporting flat bar according to the bearing capacity, respectively welding a flat bar, an upright bar and an inclined bar on the side surface, wherein the longitudinal length of a supporting frame is slightly shorter than that of an inner mold, each end is 0.1m shorter, selecting a flat ground when welding, or welding a transverse flat bar, an upright bar and an inclined bar on a special platform to form a frame of the supporting frame, and each section is provided with three supporting cross sections;

b. the manufacturing of the inner die steel plate comprises the following steps:

selecting a whole steel plate for blanking, and stamping according to the design size to form an inverted U-shaped section;

c. manufacturing the structural rib:

selecting angle steel or strip steel with proper specification, welding latticed structural ribs on a flat working surface, wherein the top surface is provided with corners and two side surfaces are respectively welded to form three blocks, and each corner part is provided with two hinge points, namely rotating points, so that the three structural ribs are connected into a whole;

three reinforcing ribs are arranged at two ends and the middle section, the ribs are in the same structure in a transverse subsection mode, square steel welding is carried out, the reinforcing ribs are used for connecting and detaching hydraulic rods on the side face of the inner die and dispersing the supporting weight on the ribs, the deformation of a steel plate is reduced, if the supporting weight is smaller, the manufacturing of the ribs is accurate, and the reinforcing ribs can be omitted;

d. the hydraulic rod piece is installed:

selecting a proper position to install a hydraulic rod piece, arranging four hydraulic rods in each section of internal mold, fixing one end of each hydraulic rod on a vertical rod, connecting the other end of each hydraulic rod on vertical structural ribs or reinforcing ribs on two sides, and arranging hinge joints at two fixed ends;

e. mounting a traveling wheel:

selecting a horizontal and solid ground, placing the top surface of the frame of the support rod piece on the ground, determining the height of the bottom walking wheels according to the designed lifting range of the internal mold, accurately positioning and leveling the ground during installation, and setting the integral lifting height to be 0.1 m;

f. integral adjustment:

adjusting a hydraulic rod to enable the positions of the net ribs on the two sides to reach the designed cross surface size, fixing the hydraulic rod, jacking the whole support by a jack and a support leg, enabling the travelling wheel to be separated from the ground and accurately leveled, lifting a stamped internal mold steel plate in place, using auxiliary measures to tightly attach the steel plate to each part of the net rib, locally performing spot welding, checking the section size and the flatness, welding the steel plate and the net rib from inside to outside one by one, adopting interval operation, avoiding centralized welding and reducing the thermal deformation of the steel plate.

6. The method of claim 5, wherein: the walking wheel is contacted with the ground, a supporting rib is arranged according to the designed position and is welded or connected with the top end of the bracket through a bolt; and (3) lapping the horizontal latticed structural ribs of the inner die on the supporting ribs on the top surface of the bracket, accurately adjusting the positions, fixing the reinforcing ribs and the structural ribs by spot welding, and accurately leveling in the welding process.

7. The method of claim 5, wherein: the supporting rod piece is integrally supported by a jack, the travelling wheel is suspended, the movable supporting leg is used for supporting and leveling, and the hydraulic rod is adjusted, so that the cross section of the internal mold conforms to the design size; and installing an end die, fixedly connecting the end die with the inner die, and then installing a side die, and fixedly connecting the side die with the side surface of the end die.

8. The method of claim 5, wherein: the method for manufacturing the internal mold of the prefabricated box culvert segment comprises the following steps:

a. the cast-in-place box culvert segment internal mold can be moved to a prefabricating field and used for horizontal segmental prefabrication of assembly type box culvert segments, the upper and lower segments of the segments are produced in an n-shaped position, the upper segment is still installed in the n-shaped position, and the lower segment is installed in the u-shaped position after being overturned by 180 degrees;

b. basic construction and manufacturing method of the segment internal mold;

(1) the inner die is fixed on a base welded by section steel, the length of the inner die is designed length, the end die and the side die are integrally arranged on a pair of trapezoidal inclined struts, and travelling wheels are arranged at the lower ends of the inclined struts and supported on longitudinal beams and transverse beams of the base;

(2) the corner part of the internal mold can be provided with hinged joints only at the upper left and upper right turning points, and the hydraulic rod is arranged as the same as the above;

(3) the bottom of the segment is provided with a socket bottom plate, the top of the segment is provided with a socket and a flat top plate, the socket bottom plate is arranged on longitudinal and transverse supporting beams of the base, and the socket top plate at the top is fixed on the side plates and the end plates;

(4) the movement of the end plate and the side plate is realized by the expansion of a hydraulic rod connected with the inclined strut and the reaction frame;

(5) the same unit is used for ensuring smooth butt joint of the bearing and the socket when the segments are installed; the socket and spigot templates are produced on the same equipment, so that the segments are well matched during prefabrication, and the visual effect of installation is improved;

(6) the template for segment prefabrication is installed and debugged as before.

9. A box culvert pouring method by using the multifunctional movable box type internal mold as claimed in any one of claims 1 to 4, comprising the following steps:

A. construction of cast-in-place box type sections:

(1) pouring the segmental floor and part of the wall:

the bottom plate and part of the side wall steel bars are manufactured and installed on site, the bottom plate and part of the side wall steel bars correspond to a lofting position, then the side mold and the end mold are erected, or the part of the end mold and the side mold are poured in an erected mode after lofting, then the steel bars are installed, the side wall vertical steel bars with full sections are completed during installation, lap joint sections are not arranged as far as possible, and the phenomenon that concrete slump is influenced by excessive density of the steel bars is avoided;

when pouring, paving and compacting the concrete of the bottom plate part at intervals, pouring the concrete of the side wall part on the basis that the concrete of the bottom plate does not flow under the pressure and vibration of the concrete of the side wall, and controlling the flatness, the cross section and the longitudinal dimension of the bottom plate to correspond to the dimension of the internal mold, the straightness of the template of the side wall part and the top elevation during pouring;

(2) pouring a top plate and the residual side walls:

after the bottom plate and the lower side wall are demolded, the whole of the multifunctional movable box-type internal mold is pulled to a design position and is accurately aligned, the internal mold is integrally jacked up, a jack is adjusted, the templates on two sides are tightly attached to the inner side of the poured side wall, the end mold is tightly attached to the end part of the poured bottom plate, the section size is checked, the adjustment is carried out through movement and lifting, then the side plate and the end plate of the internal mold are loosened, the steel bar is installed or the steel bar is installed firstly and then the template is combined, after the installation is finished, the side plate and the end plate are combined, an attached vibrator is additionally hung, and the side mold, the size; pouring and vibrating concrete layer by layer, and covering the top surface for curing;

the mold stripping sequence is as follows: firstly, loosening the connection between the segment end die and the side die and between the end die and the internal die steel plate, dismantling the side die, removing the end plates, adjusting the jacks, collecting a small amount of the two side plates and the corners to separate the two side plates and the corners from the surface of concrete, placing the jacks on the ground at the lower ends of the flat rods at the lower parts of the two ends of the support, adjusting and lifting the jacks to be tightly propped against the lower ends of the flat rods, adjusting lead screws of the support legs to fall, moving the support legs out, and adjusting the jacks to enable the support to fall slowly; the walking wheels are contacted with the bottom plate, the jack is moved out, and then the inner mold is integrally pulled out;

b. and (3) space segment cast-in-place construction:

the construction method is the same as the construction method, so that the construction of the upper part of the section is continuously carried out, when the construction is arranged, the bottom plate and part of the side wall part can be continuously poured in sequence, and the top plate and the rest of the side wall part are constructed by adopting a 'skip method';

c. and (3) middle section cast-in-place construction:

(1) firstly, installing reinforcing steel bars of the side wall of the middle section, detaching an end plate of the inner mold, simultaneously partially retracting the side wall of the inner mold through adjusting a hydraulic rod, integrally pulling the inner mold to the position of the middle section, respectively extending the lap joint sections at two ends of the inner mold into the two poured sections in proper amount and centering, placing a jack between a bottom flat rod and the ground, jacking the inner mold integrally, and tightly attaching two ends to the lower end of the top plate of the poured section;

(2) adjusting a hydraulic rod, jacking the wall parts on the two sides of the inner mold, tightly attaching the inner sides of the cast section side walls, arranging seams and settlement seams, hanging a vibrator, installing top plate steel bars and embedded parts after the side mold is in place and supported stably, and casting concrete;

(3) when the formwork is disassembled, the outer formwork is removed, the hydraulic rod is adjusted to enable the inner formwork side plate to contract inwards a little to be separated from the concrete surface, finally the jack at the lower end is tightly jacked, the supporting leg screw rod is adjusted to enable the supporting leg screw rod to be separated from the support and move out, the jack is loosened to enable the travelling wheel to contact the ground, meanwhile, the inner formwork top plate is separated from the concrete surface, and then the inner formwork is integrally pulled to the next working surface.

10. The box culvert pouring method according to claim 9, wherein: horizontal sectional construction of assembled box culvert sections:

(1) template preparation:

polishing the bottom plate, the inner mold and the side mold on the pedestal, removing dust and rust, brushing a release agent on the pedestal to enable the large surface to be smooth and flat, and adjusting a hydraulic rod to enable the inner mold to be in place and fixed firstly;

(2) manufacturing a segmental integral reinforcement cage on a special high-precision formwork, wherein the reinforcement cage can be manufactured by a segmental internal mold supporting frame, and on the basis of an original structure, a positioning toothed plate and a supporting short rib are arranged on a support according to a segmental design drawing, and a lifting appliance is manufactured according to a framework structure;

(3) after the framework is formed and tested, a lifting tool is used for lifting a framework lifting point, force is slowly applied to separate the framework lifting point from a mold frame, the lifting process is kept at a constant speed and slowly moves, the collision of an inner mold is avoided when the framework is put into the mold, the condition of a protective layer is checked after the framework is in place, deviation is corrected, and the missing cushion blocks are complemented; starting a hydraulic rod, closing and fastening the 2 end molds and the 2 side molds, processing seams, and hanging a vibrator;

(4) checking the whole size and the sealing condition after die assembly, installing embedded parts, and pouring concrete in the preformed hole in a layered mode and maintaining;

(5) after the concrete reaches the designed form removal strength, respectively loosening the fasteners and the connecting bolts between the side form and the end form, starting the jack, and respectively pulling out the side form and the end form; starting a jack on the internal mold supporting frame, pulling the internal side template of the side mold inwards to separate the internal side template from the surface of the concrete, and simultaneously separating the corner part from the concrete;

(6) hanging a hanging ring arranged on the top surface by using a special lifting appliance (the upper section of the segment is prefabricated in an inverted U-shaped position, and the top surface is provided with the hanging ring) or reserving a hanging hole on the side surface, and lifting and moving to a storage site;

for the lower section prefabricated by the U-shaped body position, a reserved hoisting hole is formed in the side surface, and the lower section is hoisted to the turnover frame by a special hoisting tool during hoisting, turned over for 180 degrees, changed into the U-shaped installation position and then hoisted to a storage site.

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