CN113352439B - Pipe sinking joint upper prefabrication device, factory method pipe sinking prefabrication system and prefabrication method - Google Patents

Pipe sinking joint upper prefabrication device, factory method pipe sinking prefabrication system and prefabrication method Download PDF

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Publication number
CN113352439B
CN113352439B CN202110414445.4A CN202110414445A CN113352439B CN 113352439 B CN113352439 B CN 113352439B CN 202110414445 A CN202110414445 A CN 202110414445A CN 113352439 B CN113352439 B CN 113352439B
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China
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immersed tube
prefabrication
reinforcement cage
factory
area
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CN113352439A (en
Inventor
林巍
林鸣
宋辉
梁杰忠
刘凌锋
吕勇刚
王勇
陈伟彬
陈猛
田英辉
刘亚平
高纪兵
董政
王晓东
邹威
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China Communications Construction Co Ltd
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China Communications Construction Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0002—Auxiliary parts or elements of the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/28—Cores; Mandrels
    • B28B7/30—Cores; Mandrels adjustable, collapsible, or expanding

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)

Abstract

The invention relates to a pipe joint upper prefabrication device, a factory method pipe prefabrication system and a prefabrication method, wherein the prefabrication device comprises a sliding beam, the sliding beam comprises a bracket and a plurality of telescopic supporting legs, an inner mold supporting frame capable of sliding longitudinally relative to the bracket is arranged on the bracket, an inner mold is sleeved outside the inner mold supporting frame, and an opening and closing device capable of expanding or contracting the inner mold is further arranged on the inner mold supporting frame; the prefabrication system comprises a prefabrication site, a lifting device, a transporting device, a first area serving as a binding area of a bottom plate and a side wall reinforcement cage, a second area serving as a binding area of a top plate reinforcement cage and a concrete pouring area, and a prefabrication device. The prefabrication device simplifies the complex process of equipment system conversion, does not need a template trimming area, and saves the prefabrication space of a pipe joint; the prefabrication system and the prefabrication method can achieve the effects of simplifying the working flow of immersed tube prefabrication, reducing the space required by immersed tube prefabrication, improving the immersed tube prefabrication efficiency and shortening the immersed tube prefabrication period.

Description

Pipe sinking joint upper prefabrication device, factory method pipe sinking prefabrication system and prefabrication method
Technical Field
The invention relates to the technical field of immersed tube tunnel construction, in particular to an upper prefabrication device of immersed tube joints, a factory immersed tube prefabrication system and a prefabrication method.
Background
The factory method immersed tube prefabrication is derived from an erle strait immersed tube tunnel (traffic in 2000), and then further developed by a port-to-ball-australia bridge immersed tube tunnel (traffic in 2018), and the traditional factory method immersed tube prefabrication assembly line comprises a steel bar binding area, a concrete pouring area, a template repairing area and an outfitting area. The steel bar binding area comprises a bottom plate steel bar, a side wall steel bar and a top plate steel bar cage binding operation of the immersed tube joint, the immersed tube joint is formed by casting a template in the concrete casting area, the template repairing area is used for repairing, maintaining and cleaning the template for completing concrete casting, and the outfitting area is used for respectively installing devices and equipment in and out of the immersed tube joint.
When the immersed tube sections are prefabricated, a single-section internal mold is generally adopted to prefabricated each immersed tube section in a segmented mode, then a plurality of immersed tube section sections are molded into the whole immersed tube section, the length of the internal mold is equal to that of one prefabricated immersed tube section, and the length of each immersed tube section is generally in the range of 15-25 m. The bottom plate, the side wall and the top plate steel bars required by prefabrication of each immersed tube segment are assembled into a steel bar cage before entering the concrete pouring internal mold; the immersed tube section is poured and pushed to advance under the action of a jack, and the inner die is required to continuously move in the pouring process of the immersed tube section. After the concrete pouring is completed, the internal mold is cleaned before the next immersed tube joint section is poured. In order to maintain the inner mould, the beam body supporting the inner mould needs to be made to a length exceeding the length of two pipe section sections so that the inner mould can be withdrawn from the cast-in-place immersed pipe section.
The traditional factory method immersed tube prefabrication assembly line has the following defects:
1. the steel bar binding area of the immersed tube prefabrication assembly line by the traditional factory method is divided into three areas of a bottom plate, a side wall and a top plate for binding, and the three areas of the bottom plate, the side wall and the top plate corresponding to all the steel bar cages, namely, the bottom plate steel bar cage binding, the side wall steel bar cage binding and the top plate steel bar cage binding work are all simultaneously arranged in the steel bar binding area, and the steel bar binding area needs higher space requirements in the length direction of the assembly line; meanwhile, the binding of the formed complete steel reinforcement cage needs to be performed in sequence of firstly binding the bottom plate steel reinforcement cage, secondly binding the side wall steel reinforcement cage and finally binding the top plate steel reinforcement cage, and then the complete steel reinforcement cage can be moved into a concrete casting area to perform next concrete casting, so that the working efficiency of the steel reinforcement binding area directly becomes key work for controlling the construction period, and the prefabrication efficiency of the whole immersed tube joint is affected;
2. in a concrete pouring area of a traditional factory-method immersed tube prefabrication assembly line, a template needs to be moved into a steel reinforcement cage, specifically, before an inner die enters the steel reinforcement cage, a top suspension system, a bottom temporary lifting system (such as a bag) and a steel reinforcement cage pushing system are additionally arranged to control deformation of the steel reinforcement cage, so that stable support of the steel reinforcement cage can be ensured, a steel reinforcement binding tire frame is withdrawn firstly, then an inner die is moved into the steel reinforcement cage, and as equipment such as the top suspension system, the bottom temporary lifting system and the steel reinforcement cage pushing system are complicated to arrange, the template needs to be frequently disassembled and assembled, and the template is moved into the steel reinforcement cage in a method of enabling the steel reinforcement cage to move from the steel reinforcement cage binding area to the concrete pouring area to be matched with the inner die, so that the conversion procedure of equipment systems of each device is complicated and the operation is difficult;
3. The traditional factory method immersed tube prefabrication assembly line still needs to set up the template repair area alone, and after the concrete placement shaping immersed tube section, the template need be followed the immersed tube section and is withdrawn, needs extra region of an immersed tube section size this moment to carry out the renovation, maintenance and clearance operation to carrying out the template, has increased assembly line operation space.
Therefore, the conventional factory method immersed tube prefabrication assembly line has the defects that the operation area is larger, the operation space requirement is higher, the operation tool operation is difficult, the operation flow is complex, the prefabrication period of a single immersed tube section is relatively longer, the prefabrication efficiency is lower, for example, a immersed tube section with the length of 180m and the weight of about 7 ten thousand tons is adopted, and the immersed tube section prefabrication can be completed in about 60 days by adopting a single assembly line of the conventional factory method immersed tube prefabrication assembly line.
Disclosure of Invention
The invention aims to overcome the defects that in the prior art, the traditional factory method immersed tube prefabrication assembly line is required to prefabricate all the concrete pouring areas of a bottom plate, a side wall and a top plate corresponding to a steel reinforcement cage, then a steel reinforcement cage top suspension system, a bottom temporary lifting system, a steel reinforcement cage pushing system and other complex equipment are adopted, a template is driven into the steel reinforcement cage to perform the next concrete pouring, the system conversion process of each device is complex, the operation is difficult, the prefabrication efficiency of the whole immersed tube joint is affected, and the invention provides an upper prefabrication device of the immersed tube joint, a factory method immersed tube prefabrication system and a factory method immersed tube prefabrication method.
In order to achieve the above object, the present invention provides the following technical solutions:
the utility model provides a immersed tube pipe section upper portion prefabrication device, includes the roof beam that slides, the roof beam that slides includes the support and locates a plurality of supporting leg that can stretch out and draw back on the support, be equipped with on the support can for the vertical gliding centre form braced frame of support, centre form braced frame overcoat is equipped with the centre form, still be equipped with on the centre form braced frame and let the centre form expand or shrink the device that opens and shuts.
The invention relates to a immersed tube joint upper prefabrication device, which comprises a sliding beam and an inner die supporting frame, wherein the inner die supporting frame is externally provided with an inner die, the sliding beam can support the inner die supporting frame and the inner die, and a plurality of telescopic supporting legs are arranged on the sliding beam, so that the immersed tube joint upper prefabrication device is positioned at a prefabrication site, a bound immersed tube joint reinforcement cage 9 can 'walk into' the immersed tube joint upper prefabrication device, and complex equipment such as a bottom temporary lifting system, a reinforcement cage pushing system and the like adopted by the existing template to 'walk into' the reinforcement cage can be omitted, the complex process of equipment system conversion is simplified, the operation is simple, the time is saved, and the prefabrication efficiency of the tube joint is improved; meanwhile, the upper prefabricating device of the immersed tube joint does not need a template trimming area, so that the prefabricating space of the tube joint is saved; the internal mold supporting frame can also longitudinally slide relative to the sliding beam, and the subsequent immersed tube joint is demolded after concrete pouring molding is completed.
Preferably, the length of the sliding beam exceeds the length of the inner die, and the two ends of the sliding beam are respectively provided with supporting legs, so that the inner die can be arranged between the two supporting legs at the end part of the sliding beam, and the supporting stability of the sliding beam on the inner die is improved.
Preferably, the inner mould and the inner mould support frame comprise N segments in the longitudinal direction, the length of the inner mould segments is matched with the length of the inner mould support frame segments, wherein N is more than or equal to 1, and N is divided into different numbers of segments according to the length of the actual prefabricated pipe joint. The inner die and the inner die supporting frame are divided into sections, and the immersed tube sections can be synchronously prefabricated in the process of dividing the sections into steps, so that the prefabrication efficiency is improved.
Preferably, the skid beam comprises the same number of skid beam sections as the inner mould support frame sections, the lengths of the skid beam sections being adapted to the inner mould support frame sections, each skid beam section being provided with at least two support legs. The support legs of the sliding beam are arranged at positions matched with the two ends of the inner mould support frame section so as to support the subsequent rapid prefabrication process of the immersed tube joint.
Preferably, all the sliding beam sections are mutually connected to form an integral structure, so that the structural strength of the sliding beam is conveniently improved; all the inner mould sections and the inner mould supporting frame sections can be respectively and independently arranged on the sliding beam in a sliding manner, so that the follow-up sectional sections are convenient to perform closure concrete pouring on the inner mould sections and demolding after pipe section concrete pouring forming.
Preferably, the inner mold and the inner mold supporting frame comprise at least three sections, namely N is more than or equal to 3, wherein the lengths of the sections are identical, so that the lengths of the sections of each pipe section formed by concrete pouring are kept consistent, and the prefabrication efficiency is improved.
Preferably, each supporting leg is provided with a telescopic device capable of enabling the supporting leg to be telescopic up and down, or is provided with a folding device capable of enabling the supporting leg to be folded. The telescopic device is a hydraulic rod, a cylinder, a jack, an electric hoist or hand equipment, so as to realize telescopic leg lifting of the support leg; the telescopic device can be replaced by a folding device, the folding device can be a supporting leg formed by hinging two rod pieces through a telescopic rod, and the telescopic rod is an electric piston rod so as to realize folding and leg lifting of the supporting leg; the support leg may also be formed of a plurality of detachable legs to effect a change in the length of the support leg.
Preferably, a longitudinal moving device is arranged between the bracket and the internal mold supporting frame so that the bracket and the internal mold supporting frame can longitudinally slide relatively.
Preferably, the longitudinal moving device is a plurality of jacks connected between the support and the internal mold supporting frame, a tank is connected between the support and the internal mold supporting frame in a sliding manner, and the tank is arranged on the support so as to realize relatively stable sliding of two larger and heavier components.
Preferably, each supporting leg upper end is equipped with the support horizontal pole, all support horizontal pole is gone up and follows slide beam is vertically to be provided with the slide rail, be provided with on the centre form braced frame and fall U type spout, the slide rail can fall U type spout and slide to when making centre form braced frame slide on the support horizontal pole, not only slide and compare the line shape, can also realize spacing effect, avoid centre form braced frame roll-off support horizontal pole.
Preferably, the inner mold supporting frame comprises a left supporting frame and a right supporting frame, the top ends of the left supporting frame and the right supporting frame are mutually hinged, the bottoms of the left supporting frame and the right supporting frame are hinged with telescopic supporting beams, the supporting beams are provided with opening and closing devices, and the opening and closing devices are jacks.
Preferably, the inner mould is fixed to the inner mould support frame by bolts or hoops or welded.
Preferably, the inner mold comprises an inner mold top plate and inner mold side plates arranged on two sides of the inner mold top plate.
Preferably, one surface of the inner mold top plate and one surface of the inner mold side plate, which are opposite to the inner mold supporting frame, are provided with stiffening angle steel I which are distributed along the longitudinal direction so as to strengthen the structural rigidity and stability of the inner mold top plate and the inner mold side plate.
The invention also provides a factory method immersed tube prefabrication system, which comprises a prefabrication site, wherein the prefabrication site comprises a first area and a second area;
the first area is a binding area of the bottom plate and the side wall reinforcement cage;
the second area is a binding area of a top plate reinforcement cage and a concrete pouring area, the second area comprises a bottom die arranged on a prefabricated site, the bottom die is provided with the prefabricated device at the upper part of the immersed tube joint, two sides of the inner die are respectively provided with side dies, each side die comprises a side die panel, and a side die supporting frame is arranged at the outer side of each side die panel;
the prefabricated site is further provided with a lifting device and a transporting device, the lifting device is used for lifting the bottom plate and the side wall reinforcement cage up and down, and the transporting device is used for transporting the bottom plate and the side wall reinforcement cage from the first area to the second area below the inner mold.
The factory method immersed tube prefabrication system comprises a first area and a second area, wherein the first area is a bottom plate and side wall reinforcement cage binding area, the second area is a top plate reinforcement cage binding area and a concrete pouring area, and the second area is also provided with the immersed tube joint upper prefabrication device. According to the system, the existing reinforcement cage binding is divided into two parts, so that the area I is subjected to the bottom plate and side wall reinforcement cage binding area, when the bound bottom plate and side wall reinforcement cage are subjected to the actions of the lifting device and the transporting device, the bottom plate and side wall reinforcement cage can 'walk into' the prefabrication device at the upper part of the immersed tube joint, the sliding beam and the inner die of the prefabrication device at the upper part of the immersed tube joint are used as a platform and then the top plate reinforcement cage is bound, a top suspension system for controlling the deformation of the reinforcement cage in the traditional factory method is omitted, the top plate reinforcement cage binding and the bottom plate and side wall reinforcement cage binding are also subjected to parallel operation, the working efficiency of the reinforcement cage binding area is improved, and the prefabrication period of the immersed tube joint is shortened; meanwhile, the prefabrication system can cancel the existing equipment which is required to be arranged in a bottom temporary lifting system, a reinforcement cage pushing system and the like adopted by a formwork to be moved into a reinforcement cage, so that the complex process of equipment system conversion is greatly simplified, and the operation tool is simple to operate; furthermore, the device for prefabricating the upper part of the immersed tube section does not need a template trimming area, so that the prefabricating space of the tube section is saved, the prefabricating process of the immersed tube section is simplified, the prefabricating period of the immersed tube section is shortened, and the prefabricating efficiency of the immersed tube section is improved.
Preferably, the inner side of the side mould panel is also provided with a plurality of split bolts which are used for being connected to the bottom plate and the side wall reinforcement cage. The split bolt can be welded with the outer side steel bars of the side wall steel reinforcement cage and is used for resisting concrete lateral fluid force in the pouring process, and compared with a side die which occupies a large width space by being supported by a gravity retaining wall, the split bolt can be arranged in a mode of reducing construction occupied space.
Preferably, a plurality of second stiffening angle steel is arranged on the outer side of the side mold panel so as to improve the rigidity of the side mold panel.
Preferably, the sideform is secured to the sideform support frame by bolts or hoops or welding.
Preferably, the bottom of the side die supporting frame is provided with a plurality of universal wheels so as to realize the movement and adjustment of random cashback.
Preferably, the bottom die is fixedly connected to the prefabricated field, so that the demoulding of the immersed tube joint after the subsequent concrete pouring and forming is facilitated.
Preferably, the transporting device comprises at least one group of track grooves respectively arranged on the prefabricated field, each group of track grooves comprises two track grooves, each track groove is internally provided with a track, a plurality of trolleys are slidably arranged on the track, the bottom plate and the side wall reinforcement cage can be transported from the first area to the second area of the prefabricated field through the plurality of trolleys, and the immersed tube joint formed by concrete pouring can be moved out of the third area. The number of the track groove groups is determined according to the number of prefabricated holes of the immersed tube joint. When only one prefabricated hole of the immersed tube section is the single Kong Chenguan tube section, the prefabricated site is enough to comprise 1 group of track grooves, and the positions of the two track grooves of the group of track grooves are respectively positioned at the corresponding positions below the side wall of the single-hole immersed tube section. When the prefabricated holes of the immersed tube pipe joint are two, namely the side-by-side double-hole immersed tube pipe joint, the prefabricated site needs to comprise 2 groups of track grooves, the 2 groups of track grooves are respectively positioned below the two prefabricated holes, namely two track grooves are formed in the corresponding positions below the side wall and the middle wall of the left prefabricated hole, and two track grooves are formed below the side wall and the middle wall of the right prefabricated hole.
Preferably, the lifting device comprises a jack arranged on each trolley, and is used for lifting the bottom plate and the side wall reinforcement cage for convenient transportation and also used for lifting the immersed tube joint formed by concrete pouring for convenient transportation.
Preferably, a step is arranged above the track groove, a movable plate is covered on the step, and when the movable plate is installed on the step, the upper surface of the movable plate is flush with the upper surface of the bottom die.
The two track grooves are respectively provided with a movable plate, when the movable plate is arranged on the step, the upper surface of the movable plate is level with the upper surface of the bottom die, and the length of the movable plate is matched with the lengths of the bottom plate and the side wall reinforcement cage sections or the inner die sections.
When the movable plate is located in the binding area of the bottom plate and the side wall reinforcement cage in the area I, the upper surface of the movable plate is level with the upper surface of the bottom plate and the side wall reinforcement cage can be used as a base plate and a base plate of the side wall reinforcement cage binding, after the bottom plate and the side wall reinforcement cage are bound, the movable plate is driven to lift through the lifting device, separation of the bottom plate and the side wall reinforcement cage from the bottom plate can be achieved, and meanwhile, the base plate serving as the bottom plate and the side wall reinforcement cage is transported to the area II through the transporting device and further transported to the lower portion of the prefabricating device on the upper portion of the immersed tube joint.
When the movable plate is positioned in the binding area of the top plate reinforcement cage and the concrete pouring area in the second area, the movable plate can be used for the function similar to that of the bottom die for concrete pouring, and after the concrete pouring is formed, the movable plate is driven to lift through the lifting device, so that the immersed tube joint formed by concrete pouring can be demolded from the bottom die, and meanwhile, the immersed tube joint can be used as a backing plate of the immersed tube joint for moving.
Preferably, the prefabricated field further comprises a third area serving as an outfitting area for prefabrication of the immersed tube joints.
The invention also provides a factory method immersed tube prefabrication method, which adopts the factory method immersed tube prefabrication system, and the immersed tube prefabrication steps comprise:
binding the bottom plate and the side wall reinforcement cage in a first prefabricated field area;
moving the bottom plate and the side wall reinforcement cage to the position below the prefabricated device at the upper part of the immersed tube joint, and moving the bound bottom plate and side wall reinforcement cage from the first region to the second region below the prefabricated device at the upper part of the immersed tube joint, wherein the bottom plate and the side wall reinforcement cage are positioned below the sliding beam and the inner die and above the bottom die, and the inner die is in a contracted state;
setting side dies, wherein the side dies and side die supporting frames thereof are respectively arranged on two sides of the bottom plate and the side wall reinforcement cage;
Binding a top plate reinforcement cage, binding the top plate reinforcement cage above the immersed tube pipe joint upper prefabrication device, and connecting the top plate reinforcement cage, the bottom plate and the side wall reinforcement cage with each other to form an integral tube joint reinforcement cage;
fifthly, pouring concrete, namely expanding an inner die of the prefabricated device at the upper part of the immersed tube section, and performing concrete pouring to form the immersed tube section;
step six, withdrawing the side mould and the immersed tube section upper prefabricating device, wherein the side mould supporting frame drives the side mould to withdraw from the side surface of the immersed tube section, the inner mould of the immersed tube section upper prefabricating device contracts, and the sliding beam and the inner mould withdraw from the inside of the immersed tube section to finish prefabricating the immersed tube section.
The factory method immersed tube prefabrication method comprises the steps of firstly binding a bottom plate and a side wall reinforcement cage in a first prefabricated field area, then moving the bottom plate and the side wall reinforcement cage to the position below an immersed tube section upper prefabrication device in a second prefabricated field area, setting a side mould and a side mould supporting frame, binding a top plate reinforcement cage by taking a sliding beam and an inner mould of the immersed tube section upper prefabrication device as a platform, then carrying out concrete pouring, and withdrawing the side mould and the immersed tube section upper prefabrication device from the immersed tube section after concrete pouring forming of the immersed tube section, thereby completing immersed tube section prefabrication. The method divides the binding of the existing reinforcement cage into two parts, so that the first area is used for binding the bottom plate and the side wall reinforcement cage, and the second area is used for binding the top plate reinforcement cage; when the bound bottom plate and the bound side wall reinforcement cage are under the action of the lifting device and the transporting device, the bottom plate and the side wall reinforcement cage can "walk into" the prefabricating device at the upper part of the immersed tube joint, so that the existing immersed tube prefabricating method can eliminate the need of arranging more complex equipment such as a bottom temporary lifting system, a reinforcement cage pushing system and the like adopted by the template to "walk into" the reinforcement cage, thereby greatly simplifying the complex process of equipment system conversion and simplifying the operation; in addition, because the binding of the top plate reinforcement cage and the binding of the bottom plate and the side wall reinforcement cage can be realized, compared with the prefabrication of the existing immersed tube joint, the template can 'walk into' the reinforcement cage and then perform concrete pouring after the whole binding of the reinforcement cage is completed by the bottom plate, the middle wall and the top plate; furthermore, the device for prefabricating the upper part of the immersed tube section does not need a template trimming area, so that the prefabricating space of the tube section is saved, the prefabricating process of the immersed tube section is simplified, the prefabricating period of the immersed tube section is shortened, and the prefabricating efficiency of the immersed tube section is improved.
In conclusion, the factory method immersed tube prefabrication method of the invention achieves the effects of simplifying the immersed tube prefabrication work flow, reducing the space required by immersed tube prefabrication, improving the immersed tube prefabrication efficiency and shortening the immersed tube prefabrication period. According to experimental comparison, aiming at a immersed tube section with the length of 180m and the weight of about 7 ten thousand tons, a single assembly line of a traditional factory immersed tube prefabrication assembly line is adopted, the immersed tube section prefabrication can be completed in about 60 days, and the immersed tube section prefabrication can be completed in 15-20 days by adopting the single assembly line of the method.
Preferably, the bottom plate and the side wall reinforcement cage in the first step are bound in sections in the first area of the prefabricated field, and the prefabricated construction method is suitable for prefabricating longer immersed tube joints.
Preferably, after the bottom plate and the side wall reinforcement cage are all moved to the lower part of the immersed tube joint upper prefabrication device, the side mould and the side mould supporting frame thereof, the binding top plate reinforcement cage and the concrete pouring forming immersed tube joint section are sequentially arranged in the sub-subsection, the forming of the next section of the immersed tube joint is carried out, and finally the prefabrication of the whole immersed tube joint is completed.
Preferably, when the immersed tube joint is concreted in the sections, concrete pouring is respectively carried out according to the interval sequence of the sections, and the immersed tube joint sections are formed in sequence. The influence of hydration heat preheating on adjacent prefabricated immersed tube joint sections during concrete pouring can be reduced as much as possible.
Preferably, the immersed tube joint length is 20-50m, and the immersed tube joint length can be several tens to several hundreds meters through a plurality of sections and the formed immersed tube joint length.
Preferably, in the implementation of the third step or/and the fourth step, the two end supporting legs of the sliding beam of the upper prefabricating device of the immersed tube joint are extended and supported on the prefabricating site, and other supporting legs between the two end supporting legs of the sliding beam are partially extended or fully extended to pass through the bottom plate and the side wall reinforcement cage to be supported on the bottom die.
Preferably, in the fifth step, when the concrete pouring is performed, the support legs of the sliding beam located in the concrete pouring area are retracted and lifted, and the support legs located at the two ends of the sliding beam are extended and supported on the prefabricated field.
Preferably, in the fifth step, when the immersed tube segment is concreted in segments, the supporting legs of the sliding beam in the concreting areas of the segments are contracted and lifted, the supporting legs of the sliding beam in the concreting areas of the non-concreted segments are stretched and supported on the bottom die, the supporting legs in the segments of the immersed tube segment which are poured are contracted and lifted or stretched and supported on the inner walls of the segments of the immersed tube segment which are poured, and the supporting legs at the two ends of the sliding beam are stretched and supported on the prefabricated field.
Preferably, in the sixth step, when the upper prefabricating device of the immersed tube section is withdrawn, the side mold supporting frame drives the side mold to withdraw from the side surface of the immersed tube section, then the immersed tube section and the upper prefabricating device of the immersed tube section are moved towards the area three together for a length l, then the upper prefabricating device of the immersed tube section is retracted from the inside of the immersed tube section to the position of the prefabricated area one, and finally the immersed tube section is removed, wherein l is smaller than the length of the immersed tube section.
Preferably, when the immersed tube joint comprises a segment of N, the specific steps of withdrawing the immersed tube joint upper prefabrication device are as follows:
step a, supporting legs at two ends of a sliding beam of a prefabricated device at the upper part of the immersed tube section are contracted and lifted, and the supporting legs of the sliding beam positioned in the immersed tube section are stretched and supported on the inner wall of the immersed tube section;
b, moving the immersed tube joint and the immersed tube joint upper prefabrication device towards a region III together for a length l;
c, expanding an inner die of the prefabricated device at the upper part of the immersed tube joint through an opening and closing device supported by an inner die supporting frame, supporting the inner die on the inner wall of the immersed tube joint, and shrinking and lifting all supporting legs of the sliding beam;
D, keeping the immersed tube section, the inner die and the inner die supporting frame fixed, backing the sliding beam from the immersed tube section to a prefabricated site, and extending supporting legs of the sliding beam outside the immersed tube section and supporting the prefabricated site;
step e, contracting the inner mold supporting frame to drive the inner mold to be folded and contracted, wherein the inner mold supporting frame drives the inner mold to retract from the immersed tube section along the sliding beam;
and f, removing the immersed tube section until the sliding beam and the internal mold of the immersed tube section upper prefabricating device are all retracted from the immersed tube section, thereby completing the prefabrication of the immersed tube section.
Preferably, when the step d is performed, if the sliding beam cannot be retracted from the immersed tube section to the second initial position of the prefabricated field area at one time, after the sliding beam is retracted from the immersed tube section by the distance m, the step e is performed, and then the steps d and e are repeated in a circulating manner until the sliding beam is retracted from the immersed tube section to the second initial position of the prefabricated field area, and then the step f is performed.
Preferably, the retraction distance m of the sliding beam from the immersed tube section is one section length value of the immersed tube section.
Preferably, the immersed tube segment and the immersed tube segment upper prefabrication means are moved together forward (i.e. in three directions) by a length l equal to the length of N-1 segments of the immersed tube segment. It should be noted that the value of l should be several times of the unit section length of the immersed tube section number N, and comprehensive analysis is performed according to the immersed tube section specific section number, so as to ensure that the whole system can be balanced and stable when the immersed tube section upper portion pre-manufacturing device exits. For example, when n=3, the immersed tube segment comprises 3 segments, and therefore, in the step b, the value of the moving length l of the immersed tube segment and the immersed tube segment upper prefabrication device together towards the area three is equal to the value of the segment length of 2 immersed tube segments, so that the whole system can be balanced and stable when the immersed tube segment upper prefabrication device exits; when n=5, the immersed tube segment comprises 5 segments, and the value of the moving length l of the immersed tube segment and the immersed tube segment upper prefabrication device together towards the region three in the step b is not necessarily equal to the value of the segment length of 4 immersed tube segments, the value of the segment length of 3 immersed tube segments can be adopted, and the whole system can be balanced and stable when the immersed tube segment upper prefabrication device exits; and so on.
Preferably, the immersed tube joint is lifted and transported by a lifting device and a transporting device arranged on the prefabricated site respectively.
Preferably, after the step six is implemented, the prefabricated immersed tube segment is moved to an outfitting area, namely an area three of a prefabricated site, and then the steps one to six are repeated to perform the prefabrication of the next immersed tube segment.
Preferably, after the bottom plate and the side wall reinforcement cage of the previous immersed tube section in implementing the second step are moved from the first region to the second region below the prefabrication device at the upper part of the immersed tube section, the first step can be implemented in the first prefabrication field region to implement the first step for binding the bottom plate and the side wall reinforcement cage of the next immersed tube section. The roof reinforcement cage binding and concrete pouring form parallel flow synchronous operation with the bottom plate and the side wall reinforcement cage binding, so that the construction time can be further saved, and the prefabricating efficiency of a plurality of immersed tube joints can be further improved.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention relates to a immersed tube joint upper prefabrication device, which comprises a sliding beam and an inner die supporting frame, wherein the inner die is arranged outside the inner die supporting frame, the sliding beam can support the inner die supporting frame and the inner die, and a plurality of telescopic supporting legs are arranged on the sliding beam, so that the immersed tube joint upper prefabrication device is positioned at a prefabrication site, a bound immersed tube joint reinforcement cage can 'walk into' the immersed tube joint upper prefabrication device, and complex equipment such as a bottom temporary lifting system, a reinforcement cage pushing system and the like adopted by the existing template to 'walk into' the reinforcement cage can be omitted, the complex process of equipment system conversion is simplified, the operation is simple, the time is saved, and the prefabrication efficiency of the tube joint is improved; meanwhile, the upper prefabricating device of the immersed tube joint does not need a template trimming area, so that the prefabricating space of the tube joint is saved; the inner mold supporting frame can also longitudinally slide relative to the sliding beam, so that demoulding after concrete pouring forming is finished on the aspect of the subsequent immersed tube joint;
2. The factory method immersed tube prefabrication system comprises a first area and a second area, wherein the first area is a baseboard and side wall reinforcement cage binding area, the second area is a roof reinforcement cage binding area and a concrete pouring area, and the second area is also provided with an immersed tube joint upper prefabrication device. According to the system, the existing reinforcement cage binding is divided into two parts, so that the area is divided into two parts, the bottom plate and the side wall reinforcement cage binding areas are formed, when the bound bottom plate and side wall reinforcement cage are under the action of the lifting device and the transporting device, the bottom plate and side wall reinforcement cage can 'walk into' the prefabrication device at the upper part of the immersed tube joint, the sliding beam and the inner die of the prefabrication device at the upper part of the immersed tube joint are used as a platform and then the top plate reinforcement cage binding is carried out, and therefore a top suspension system for controlling the deformation of the reinforcement cage in a traditional factory method is omitted, parallel operation can be realized by binding the top plate reinforcement cage with the bottom plate and the side wall reinforcement cage, the working efficiency of the reinforcement cage binding area is improved, and the prefabrication period of the immersed tube joint is shortened; meanwhile, the prefabrication system can cancel the existing equipment which is required to be arranged in a bottom temporary lifting system, a reinforcement cage pushing system and the like adopted by a formwork to be moved into a reinforcement cage, so that the complex process of equipment system conversion is greatly simplified, and the operation tool is simple to operate; furthermore, the upper prefabricating device of the immersed tube joint does not need a template trimming area, so that the prefabricating space of the immersed tube joint is saved, the prefabricating process of the immersed tube joint is simplified, the prefabricating period of the immersed tube joint is shortened, and the prefabricating efficiency of the immersed tube joint is improved;
3. The factory method immersed tube prefabrication method comprises the steps of firstly binding a bottom plate and a side wall reinforcement cage in a first prefabricated field area, then moving the bottom plate and the side wall reinforcement cage to the position below an immersed tube joint upper prefabrication device in a second prefabricated field area, setting a side mould and a side mould supporting frame, binding a top plate reinforcement cage by taking a sliding beam and an inner mould of the immersed tube joint upper prefabrication device as a platform, then carrying out concrete pouring, and withdrawing the side mould and the immersed tube joint upper prefabrication device from the immersed tube joint after concrete pouring forming of the immersed tube joint, thereby completing immersed tube joint prefabrication. The method divides the binding of the existing reinforcement cage into two parts, so that the first area is used for binding the bottom plate and the side wall reinforcement cage, and the second area is used for binding the top plate reinforcement cage; when the bound bottom plate and the side wall reinforcement cage are under the action of the lifting device and the transporting device, the bottom plate and the side wall reinforcement cage can "walk into" the prefabricating device at the upper part of the immersed tube joint, so that the traditional immersed tube prefabricating method can eliminate the equipment which is relatively complicated in arrangement, such as a bottom temporary lifting system, a reinforcement cage pushing system and the like, adopted by the template to "walk into" the reinforcement cage, thereby greatly simplifying the complex process of equipment system conversion and being simple to operate; in addition, because the binding of the top plate reinforcement cage and the binding of the bottom plate and the side wall reinforcement cage can be realized, compared with the prefabrication of the existing immersed tube joint, the template can 'walk into' the reinforcement cage and then perform concrete pouring after the whole binding of the reinforcement cage is completed by the bottom plate, the middle wall and the top plate; furthermore, the device for prefabricating the upper part of the immersed tube section does not need a template trimming area, so that the prefabricating space of the tube section is saved, the prefabricating process of the immersed tube section is simplified, the prefabricating period of the immersed tube section is shortened, the prefabricating efficiency of the immersed tube section is improved, and the device is suitable for quickly prefabricating the single-hole or multi-hole immersed tube section.
Description of the drawings:
FIG. 1 is a schematic view of an upper prefabrication device for immersed tube joints according to the present invention;
FIG. 2 is a schematic view of the skid beam of FIG. 1;
FIG. 3 is a schematic view of the structure of the skid beam support leg of FIG. 2;
FIG. 4 is a schematic view of three variations of the skid beam support leg of FIG. 2;
FIG. 5 is a schematic view of the inner mold and inner mold support frame of FIG. 1 in an expanded configuration;
FIG. 6 is a plan view of the inner mold and inner mold support frame of FIG. 5 when expanded;
FIG. 7 is a schematic view of the inner mold and the inner mold support frame of FIG. 5 in a contracted configuration;
FIG. 8 is a plan view of the inner mold and inner mold support frame of FIG. 7 as it is contracted;
FIG. 9 is a schematic diagram of a factory-process immersed tube prefabrication system according to the present invention;
FIG. 10 is another schematic view of FIG. 9;
FIG. 11 is a schematic view of a factory-method immersed tube prefabrication system according to the invention, wherein the bottom plate and side wall reinforcement cages and the top plate reinforcement cage are bound by the first and second sections at the same time;
FIG. 12 is a connection block diagram of a side form and side form support frame;
FIG. 13 is a schematic view of a structure of a pipe section of a immersed pipe formed by casting concrete;
fig. 14 is an enlarged view of a portion a in fig. 13;
FIG. 15 is a schematic view of a construction for lifting a immersed tube section by a lifting device for demoulding;
Fig. 16 is an enlarged view of a portion B in fig. 15;
fig. 17 is a diagram showing distribution of each segment of a reinforcement cage, each segment of an inner mold, each segment of a pipe section in a prefabricated field;
FIG. 17a is an initial state diagram of a prefabricated immersed tube section at a prefabricated site using a factory method immersed tube prefabrication method;
fig. 17b is a schematic view of the reinforcement cage fully lifted up on the fifth and sixth support legs before being displaced from zone one to zone two;
FIG. 17C is an enlarged schematic view of the partial area C in FIG. 17 b;
fig. 17d is a schematic view of the first reinforcement cage segment B1 displaced into the second inner mold segment three F3;
fig. 17e is a schematic view of a first reinforcement cage segment B1 displaced into a second inner mold segment F2 of region two;
fig. 17F is a schematic view of the first reinforcement cage segment B1 displaced into the first inner mold segment F1 of region two;
fig. 17g is a schematic view of a second reinforcement cage segment B2 displaced into an inner mold segment three F3 of region two;
fig. 17h is a schematic illustration of a second reinforcement cage segment B2 being displaced into an inner mold segment B2 of region two;
fig. 17i is a schematic view of the third B3 rebar cage segment displaced into the third F3 inner mold segment of region two;
FIG. 17j is a schematic view of the six support legs L6 of FIG. 17i raised to lowered ready for placement;
FIG. 17k is a schematic view of the interior of the hidden portion of FIG. 17j showing the skid beam;
FIG. 17k-1 is a longitudinal cross-sectional view of region two of FIG. 17 j;
FIG. 17k-2 is a cross-sectional view C-C of FIG. 17 k-1;
FIG. 17l is a schematic illustration of the side form support frame being displaced to a position of reinforcement cage segment B1 for banding the roof reinforcement cage;
FIG. 17l-1 is a longitudinal cross-sectional view of region two of FIG. 17 l;
FIG. 17l-2 is a sectional view D-D of FIG. 17 l-1;
FIG. 17m is a schematic view of the support leg two L2 of FIG. 17L stowed with the inner mold support frame deployed in preparation for casting reinforcement cage segment one B1;
FIG. 17m-1 is a longitudinal cross-sectional view of region two of FIG. 17 m;
FIG. 17m-2 is a cross-sectional view E-E of FIG. 17 m-1;
fig. 17n is an illustration of a concrete placement of section one S1 of the formed tube segment while binding the top plate reinforcement cage at section three B3 of the reinforcement cage;
FIG. 17n-1 is a longitudinal cross-sectional view of region two in FIG. 17 n;
FIG. 17n-2 is a cross-sectional view of G-G of FIG. 17 n-1;
FIG. 17o is an illustration of a concrete placement of a third S3 formed tube segment while binding a top plate reinforcement cage at a second B2 reinforcement cage segment;
FIG. 17o-1 is a longitudinal cross-sectional view of region two of FIG. 17 o;
FIG. 17p is a schematic view of a fifth L5 support leg supported on the inner wall of section III S4 and a second S2 concrete placement molding section;
FIG. 17p-1 is a longitudinal cross-sectional view of region two in FIG. 17 p;
FIG. 17q is a view of a transfer device moving a immersed tube segment of zone two forward a distance a of the two tube segment lengths;
FIG. 17r is a view of all support legs raised and supported on the inner mold and retracted by a slip Liang Chaohou a distance b of one pipe segment length;
FIG. 17s illustrates a six L6 drop down support leg, a one L1 support leg, resting on the inner wall of the immersed tube segment, while retracting the inner mold segment two F2 and the inner mold segment three F3 a distance of one tube segment length;
FIG. 17t shows the support legs Liang San L3 resting on the inner wall of the immersed tube segment, the support leg L1 fully raised, the inner mold segment F1 retracted one segment length;
FIG. 17u shows the inner mold deployed and supported on the inner wall of the immersed tube segment with all support legs fully raised and the inner mold retracted by force a distance of one segment length;
FIG. 17v illustrates a six L6 drop down support leg, a one L1 support leg, a two F2 inner mold segment, a three F3 inner mold segment, and a force slippage Liang Huitui distance of one pipe segment length;
FIG. 17w illustrates the support legs Liang San L3 and four support legs L4 lowered, the support leg one L1 raised, the inner mold section one F1 contracted and slid Liang Huitui by force a distance of one pipe section segment length;
FIG. 17x illustrates a transfer device transferring a immersed tube section away to achieve complete demolding from the inner mold;
Fig. 17y is a schematic view of fig. 17a, showing three areas of the prefabricated field all returning to the original state.
The marks in the figure:
100. immersed tube joints, 101, zone one, 102, zone two, 103, zone three, 1, slipping beams, 11, brackets, 12, support crossbars, 13, support legs, 14, slide rails, 15, opening and closing devices, 2, internal molds, 21, internal mold top plates, 22, internal mold side plates, 23, stiffening angle one, 3, internal mold support frames, 31, opening and closing devices, 32, left support frames, 33, right support frames, 34, support crossbars, 35, slide grooves, 4, longitudinal moving devices, 5, prefabricated fields, 51, track grooves, 52, tracks, 53, steps, 54, movable plates, 55, moving devices, 56, lifting devices, 6, bottom molds, 7, side molds, 71, side mold panels, 72, split bolts, 73, stiffening angle two, 8, side mold support frames, 81, longitudinal connecting beams, 82, universal wheels, 9, immersed tube reinforcement cages, 91, bottom plates and side wall reinforcement cages, 92, top plate reinforcement cages;
b1, a first reinforcement cage section, a second reinforcement cage section, a B3, a third reinforcement cage section, a F1, an inner mold section, a F2, an inner mold section, a F3, an inner mold section, a L1, a first supporting leg, a L2, a second supporting leg, a L3, a third supporting leg, a L4, a fourth supporting leg, a L5, a fifth supporting leg, a L6, a sixth supporting leg, a S1, a first pipe section, a S2, a second pipe section, a S3 and a third pipe section.
Detailed Description
The present invention will be described in further detail with reference to test examples and specific embodiments. It should not be construed that the scope of the above subject matter of the present invention is limited to the following embodiments, and all techniques realized based on the present invention are within the scope of the present invention.
Example 1
As shown in fig. 1-8, embodiment 1 provides a prefabricated device on the upper portion of a immersed tube joint 100, which comprises a sliding beam 1, wherein the sliding beam 1 comprises a bracket and a plurality of telescopic supporting legs 13 arranged on the bracket, an inner die supporting frame 3 capable of sliding longitudinally relative to the bracket is arranged on the bracket, an inner die 2 is sleeved outside the inner die supporting frame 3, and an opening and closing device 15 capable of expanding or contracting the inner die 2 is further arranged on the inner die supporting frame 3.
As shown in fig. 2-4, the length of the sliding beam 1 exceeds the length of the inner die 2, and the two ends of the sliding beam 1 are respectively provided with a supporting leg 13, so that the inner die 2 can be arranged between the two supporting legs 13 at the end part of the sliding beam 1, and the supporting stability of the sliding beam 1 to the inner die 2 is improved.
As shown in fig. 5-6, the segments of the inner mold 2 and the inner mold supporting frame 3 respectively comprise N segments along the longitudinal direction, the length of the segment of the inner mold 2 is matched with the length of the segment of the inner mold supporting frame 3, wherein N is more than or equal to 1, and N is divided into different numbers of segments according to the length of an actual prefabricated pipe segment so as to improve the prefabrication efficiency. N=3 as shown in fig. 9.
Further, the slippage beam 1 comprises the same number of slippage beam 1 sections as the sections of the internal mold support frame 3, the lengths of the slippage beam 1 sections are matched with the lengths of the sections of the internal mold support frame 3, and each slippage beam 1 section is provided with at least two support legs 13. All the sections of the sliding beam 1 are mutually connected to form an integral structure, so that the structural strength of the sliding beam 1 is conveniently improved; all the sections of the internal mold supporting frame 3 are respectively and independently arranged on the sliding beam 1 in a sliding manner, so that the subsequent sections of the internal mold 2 can be conveniently subjected to folding concrete pouring and demolding after pipe section concrete pouring molding. The lengths of all the sections of the internal mold 2 are the same, so that the lengths of all the pipe sections formed by concrete pouring are kept consistent, and the prefabrication efficiency is improved.
As shown in fig. 4, in addition, each supporting leg 13 is provided with a telescopic device capable of enabling the supporting leg 13 to extend and retract up and down, and the telescopic device is a hydraulic rod, a cylinder, a jack, an electric hoist or hand equipment so as to realize the extension and lifting of the supporting leg 13; the telescopic device can be replaced by a folding device, the folding device can be a supporting leg 13 formed by hinging two rod pieces through a telescopic rod, and the telescopic rod is an electric piston rod so as to realize folding and leg lifting of the supporting leg 13; the support leg 13 may also be formed of a plurality of detachable legs to effect a change in length of the support leg 13.
A longitudinal moving device 4 is arranged between the bracket and the internal mold supporting frame 3 so that the bracket and the internal mold supporting frame 3 can longitudinally slide relatively. The longitudinal moving device 4 is a plurality of jacks connected between the support and the inner die supporting frame 3, and tank wheels are connected between the support and the inner die supporting frame 3 in a sliding manner so as to realize stable sliding of two larger and heavier components.
The upper end of each supporting leg 13 is provided with a supporting cross rod 12, all the supporting cross rods 12 are longitudinally provided with sliding rails 14 along the sliding beam 1, the inner mold supporting frame 3 is provided with an inverted U-shaped sliding groove 35, and the sliding rails 14 can slide on the inverted U-shaped sliding groove 35, so that when the inner mold supporting frame 3 slides on the supporting cross rods 12, the inner mold supporting frame 3 can slide relatively linearly, and the limiting effect can be realized, and the inner mold supporting frame 3 is prevented from sliding out of the supporting cross rods 12.
As shown in fig. 6 to 8, the above-mentioned inner mold support frame 3 includes a left support frame 32 and a right support frame 33, the top ends of the left support frame 32 and the right support frame 33 are hinged to each other, the bottoms of the left support frame 32 and the right support frame 33 are hinged to a telescopic support beam 34, and an opening and closing device 15 is provided on the support beam 34, and the opening and closing device 15 is a jack. The inner mould 2 is fixed on the inner mould supporting frame 3 by bolts or hoops or welding.
The inner mold 2 includes an inner mold top plate 21 and inner mold side plates 22 provided on both sides of the inner mold top plate 21. One side of the inner mold top plate 21 and one side of the inner mold side plate 22, which are opposite to the inner mold supporting frame 3, are provided with stiffening angle steel I23 distributed along the longitudinal direction so as to strengthen the structural rigidity and stability of the inner mold top plate 21 and the inner mold side plate 22.
The invention relates to a pipe joint 100 upper prefabrication device of immersed tube, which comprises a sliding beam 1 and an inner die supporting frame 3, wherein an inner die 2 is arranged outside the inner die supporting frame 3, the sliding beam 1 can support the inner die supporting frame 3 and the inner die 2, and a plurality of telescopic supporting legs 13 are arranged on the sliding beam 1, so that the pipe joint 100 upper prefabrication device can be positioned at a prefabrication site 5 original position, a bound steel reinforcement cage of the immersed tube 100 can be moved into the pipe joint 100 upper prefabrication device, and complex equipment such as a bottom temporary lifting system, a steel reinforcement cage pushing system and the like adopted by the existing template moved into the steel reinforcement cage can be omitted, the complex procedure of equipment system conversion is simplified, the operation is simple, the time is saved, and the pipe joint prefabrication efficiency is improved; meanwhile, the upper prefabricating device of the immersed tube joint 100 does not need a template trimming area, so that the prefabricating space of the tube joint is saved; the internal mold supporting frame 3 can also longitudinally slide relative to the sliding beam 1, and the subsequent immersed tube joint 100 can be demolded after concrete pouring molding.
Example 2
As shown in fig. 9-11, embodiment 2 provides a factory method immersed tube prefabrication system, which comprises a prefabrication site 5, wherein the prefabrication site 5 comprises a first area 101 and a second area 102;
the first area 101 is a binding area of the bottom plate and the side wall reinforcement cage 91;
the second area 102 is a binding area of the top plate reinforcement cage 92 and a concrete pouring area, the second area 102 comprises a bottom die 6 arranged on the prefabricated site 5, the bottom die 6 is provided with the prefabricated device at the upper part of the immersed tube joint 100, two sides of the inner die 2 are respectively provided with side dies 7, each side die 7 comprises a side die panel 71, and a side die supporting frame 8 is arranged outside each side die panel 71;
the prefabricated place 5 is further provided with a lifting device 56 and a transporting device 55, the lifting device 56 is used for lifting the bottom plate and the side wall reinforcement cage up and down, and the transporting device 55 is used for transporting the bottom plate and the side wall reinforcement cage from the first area 101 to the second area 102 below the inner mold 2.
As shown in fig. 12, the inner side of the side form 71 is further provided with a plurality of split bolts 72 for connecting to the bottom plate and the side wall reinforcement cage. Specifically, the threaded rod of the split bolt 72 is connected to the side mold plate 71, the nut faces the inner side of the side mold plate 71, the nut can be welded with the outer steel bar of the side wall steel bar cage, and is used for resisting the lateral fluid force of concrete in the pouring process, and compared with the side mold 7, the mode of arranging the split bolt 72 can reduce the construction occupied space if the split bolt is supported by a gravity retaining wall and occupies a large width space. The outer side of the side mold plate 71 is provided with a plurality of stiffening angle steel II 73 to improve the rigidity of the side mold plate 71. The sideform 7 is secured to the sideform support frame 8 by bolts or hoops or welding. The side mold support frame 8 is transversely provided with a plurality of longitudinal connecting beams 81 on the surface thereof to strengthen the strength of the side mold support frame 8, and a plurality of universal wheels 82 are arranged at the bottom thereof to realize the movement and adjustment of arbitrary cashing.
The bottom die 6 is fixedly connected to the prefabricated site 5, so that the sinking pipe joint 100 can be conveniently demolded after the subsequent concrete pouring and forming.
The transfer device 55 includes two sets of track grooves, the number of track groove sets being determined according to the number of prefabricated holes of the immersed tube segment 100. When there is only one prefabricated hole of the immersed tube segment 100, as shown in fig. 13-16, that is, when the immersed tube segment 100 is a single Kong Chenguan tube segment 100, it is sufficient that the prefabricated place 5 includes 1 set of track grooves, and two track grooves 51 of the set of track grooves are respectively located at corresponding positions below the side walls of the single immersed tube segment 100. If there are two prefabricated holes of the pipe section 100, as shown in fig. 17k-2, that is, the side-by-side double-hole pipe section, the prefabricated site 5 needs to include 2 sets of track grooves, where the 2 sets of track grooves are located below the two prefabricated holes, that is, two track grooves 51 are disposed at corresponding positions below the side wall and the middle wall of the left prefabricated hole, and two track grooves 51 are disposed below the side wall and the middle wall of the right prefabricated hole.
Specifically, as shown in fig. 13-16, the set of track grooves are respectively arranged on two track grooves 51 on the prefabricated site 5, a track 52 is arranged in each track groove 51, a plurality of trolleys are slidably arranged on the track 52, and the bottom plate and the side wall reinforcement cage can be moved from the first area 101 to the second area 102 through the plurality of trolleys, so that the immersed tube joint 100 formed by concrete pouring can be moved out of the third area 103. The lifting device 56 comprises a jack arranged on each trolley and is used for lifting the bottom plate and the side wall reinforcement cage to facilitate transportation and also used for lifting the immersed tube joint 100 formed by concrete pouring to facilitate transportation. The transfer device 55 and the lifting device 56 can be integrated into one system for use.
A step 53 is arranged above the track groove 51, the step 53 is covered with a movable plate 54, when the movable plate 54 is installed on the step 53, the upper surface of the movable plate 54 is flush with the upper surface of the bottom die 6, the movable plate 54 is a steel plate, and the thickness of the movable plate 54 is thicker than that of the bottom die 6 fixed on the prefabricated field 5. The two track grooves 51 are respectively provided with a movable plate 54, when the movable plate 54 is installed on the step 53, the upper surface of the movable plate 54 is flush with the upper surface of the bottom die 6, the length of the movable plate 54 is matched with the length of the bottom plate and the side wall reinforcement cage section or the inner die 2 section, and the movable plate 54 has the following functions:
(1) when the movable plate 54 is located in the binding area of the bottom plate and the side wall reinforcement cage 91 in the first area 101, the upper surface of the movable plate 54 is flush with the upper surface of the bottom die 6, and can be used as a base plate for binding the bottom plate and the side wall reinforcement cage 91, after the bottom plate and the side wall reinforcement cage 91 are bound, the movable plate 54 is driven to lift through the lifting device 56, separation of the bottom plate and the side wall reinforcement cage from the bottom die 6 can be achieved, and meanwhile, the base plate serving as the bottom plate and the side wall reinforcement cage is moved to the second area 102 through the moving device 55 and is further moved to the lower portion of the prefabricated device on the upper portion of the immersed tube section 100.
(2) In the binding area of the top plate reinforcement cage 92 and the concrete pouring area when the movable plate 54 is positioned in the second area 102, the movable plate 54 is driven to lift by the lifting device 56 after the concrete pouring molding, so that the immersed tube segment 100 formed by the concrete pouring can be demolded from the bottom die 6, and meanwhile, the immersed tube segment 100 can be used as a backing plate for transporting the immersed tube segment 100.
The prefabrication site 5 further comprises an area three 103 as an outfitting area for prefabrication of the immersed tube sections 100.
The factory method immersed tube prefabrication system comprises a first area 101 and a second area 102, wherein the first area 101 is a binding area of a bottom plate and side wall reinforcement cages 91, the second area 102 is a binding area of a top plate reinforcement cage 92 and a concrete pouring area, and the second area 102 is also provided with an upper prefabrication device of an immersed tube joint 100.
According to the system, the existing reinforcement cage binding is divided into two parts, so that the first area 101 is only used for a binding area of the bottom plate and the side wall reinforcement cage 91, when the bound bottom plate and side wall reinforcement cage are under the action of the lifting device 56 and the transporting device 55, the bound bottom plate and side wall reinforcement cage can 'walk into' the prefabrication device at the upper part of the immersed tube joint 100, the sliding beam 1 and the inner mould 2 of the prefabrication device at the upper part of the immersed tube joint 100 are used as a platform to bind the top plate reinforcement cage 92, and therefore a top suspension system for controlling the deformation of the reinforcement cage in a traditional factory method is omitted, parallel operation of the binding of the top plate reinforcement cage 92 and the bottom plate and the side wall reinforcement cage 91 can be realized, the working efficiency of the binding area of the reinforcement cage is improved, and the prefabrication period of the immersed tube joint 100 is shortened; meanwhile, the prefabrication system can cancel the existing equipment which is required to be arranged in a bottom temporary lifting system, a reinforcement cage pushing system and the like adopted by a formwork to be moved into a reinforcement cage, so that the complex process of equipment system conversion is greatly simplified, and the operation tool is simple to operate; furthermore, the device for prefabricating the upper part of the immersed tube segment 100 does not need a template trimming area, so that the tube segment prefabricating space is saved, the tube segment 100 prefabricating process is simplified, the prefabricating period of the immersed tube segment 100 is shortened, and the prefabricating efficiency of the immersed tube segment 100 is improved.
Example 3
The embodiment 3 provides a factory method immersed tube prefabrication method, adopting the factory method immersed tube prefabrication system, the immersed tube prefabrication steps comprise:
step one, binding a bottom plate and a side wall reinforcement cage, and binding the bottom plate and the side wall reinforcement cage in a first area 101 of a prefabricated site 5;
moving the bottom plate and the side wall reinforcement cage to the lower part of the prefabricated device at the upper part of the immersed tube joint 100, and moving the bound bottom plate and side wall reinforcement cage from the first region 101 to the second region 102 to the lower part of the prefabricated device at the upper part of the immersed tube joint 100, wherein the bottom plate and the side wall reinforcement cage are positioned below the sliding beam 1 and the inner die 2 and above the bottom die 6, and the inner die 2 is in a contracted state;
setting side dies 7, and respectively setting the side dies 7 and side die supporting frames 8 thereof on two sides of the bottom plate and the side wall reinforcement cage;
binding a top plate reinforcement cage 92, binding the top plate reinforcement cage 92 above the prefabricated device on the upper part of the immersed tube joint 100, and connecting the top plate reinforcement cage 92, the bottom plate reinforcement cage and the side wall reinforcement cage to form an integral tube joint reinforcement cage;
fifthly, pouring concrete, namely expanding an inner die 2 of the prefabricating device at the upper part of the immersed tube joint 100, and performing concrete pouring to form the immersed tube joint 100;
Step six, withdrawing the side die 7 and the prefabricating device on the upper part of the immersed tube segment 100, wherein the side die supporting frame 8 drives the side die 7 to withdraw from the side surface of the immersed tube segment 100, the inner die 2 of the prefabricating device on the upper part of the immersed tube segment 100 contracts, and the sliding beam 1 and the inner die 2 withdraw from the inside of the immersed tube segment 100 to finish prefabricating the immersed tube segment 100.
Preferably, the bottom plate and the side wall reinforcement cage in the first step are bound in sections in the first area 101 of the prefabricated field 5, so that the prefabricated immersed tube joint 100 is suitable for prefabrication of a longer immersed tube joint.
After the bottom plate and the side wall reinforcement cage segments are all moved below the prefabricating device on the upper portion of the immersed tube segment 100, then the side dies 7 and the side die supporting frames 8 thereof, the binding top plate reinforcement cage 92 and the concrete pouring forming immersed tube segment 100 segments are sequentially arranged in the subsections respectively, then the forming of the next segment of the immersed tube segment 100 is carried out, and finally the prefabrication of the whole immersed tube segment 100 is completed.
When the immersed tube segment 100 is concreted in the segments, concrete is respectively concreted according to the segment interval sequence, and the immersed tube segment 100 segments are formed in sequence. The influence of hydration heat preheating on the adjacent prefabricated immersed tube segment 100 sections during concrete pouring can be reduced as much as possible. The immersed tube section 100 has a section length of 20-50m, and the length of the immersed tube section 100 can be tens to hundreds of meters different from that of the formed immersed tube section 100.
In the implementation of the third step and/or the fourth step, the two supporting legs 13 of the sliding beam 1 of the prefabricated device at the upper part of the immersed tube segment 100 are extended and supported on the prefabricated site 5, and the other supporting legs 13 between the two supporting legs 13 of the sliding beam 1 are partially extended or fully extended to pass through the bottom plate and the side wall reinforcement cage and are supported on the bottom die 6.
In the fifth step, when the concrete is poured, the support legs 13 of the sliding beam 1 located in the concrete pouring area are contracted and lifted, and the support legs 13 located at the two ends of the sliding beam 1 are extended and supported on the prefabricated site 5. In addition, when the immersed tube segment 100 is concreted in the segments in the step five, the supporting legs 13 of the sliding beam 1 positioned in the segment concreting area are contracted and lifted, the supporting legs 13 of the sliding beam 1 positioned in the non-concreting segment concreting area are stretched and supported on the bottom die 6, the supporting legs 13 positioned in the segment of the immersed tube segment 100 which is poured and lifted or stretched and supported on the inner wall of the segment 100 which is poured and completed, and the supporting legs 13 positioned at the two ends of the sliding beam 1 are stretched and supported on the prefabricated site 5.
In the sixth step, when the prefabricating device at the upper part of the immersed tube segment 100 is withdrawn, the side mold supporting frame 8 drives the side mold 7 to withdraw from the side surface of the immersed tube segment 100, then the immersed tube segment 100 and the prefabricating device at the upper part of the immersed tube segment 100 are moved towards the third area 103 together by a length l, then the prefabricating device at the upper part of the immersed tube segment 100 is retracted from the inside of the immersed tube segment 100 to the position of the first area 101 of the prefabricating site 5, and finally the immersed tube segment 100 is removed, wherein l is smaller than the length of the immersed tube segment 100.
In particular, when the immersed tube segment 100 includes N segments, the specific steps of withdrawing the prefabricated device at the upper portion of the immersed tube segment 100 are as follows:
step a, the supporting legs 13 at the two ends of the sliding beam 1 of the prefabricated device at the upper part of the immersed tube section 100 are contracted and lifted, and the supporting legs 13 of the sliding beam 1 positioned in the immersed tube section 100 are stretched and supported on the inner wall of the immersed tube section 100;
step b, moving the immersed tube segment 100 and the prefabricated device on the upper part of the immersed tube segment 100 forwards by a length l;
step c, the inner mould 2 of the prefabricated device at the upper part of the immersed tube joint 100 is unfolded through the opening and closing device 15 supported by the inner mould supporting frame 3 and is supported on the inner wall of the immersed tube joint 100, so that all supporting legs 13 of the sliding beam 1 are contracted and lifted;
step d, keeping the immersed tube joint 100, the inner die 2 and the inner die supporting frame 3 fixed, backing the sliding beam 1 from the immersed tube joint 100 to the prefabricated site 5, and extending the supporting legs 13 of the sliding beam 1 positioned outside the immersed tube joint 100 and supporting the sliding beam on the prefabricated site 5;
step e, the inner die supporting frame 3 is contracted to drive the inner die 2 to be folded and contracted, and the inner die supporting frame 3 drives the inner die 2 to retract from the immersed tube section 100 along the sliding beam 1;
And f, removing the immersed tube joint 100 until the sliding beam 1 and the internal mold 2 of the upper prefabrication device of the immersed tube joint 100 are all retracted from the immersed tube joint 100, thereby completing prefabrication of the immersed tube joint 100.
In the step d, if the sliding beam 1 cannot be retracted from the immersed tube segment 100 to the initial position of the second prefabricated area 5 area 102 at one time, the step e is performed after the sliding beam 1 is retracted from the immersed tube segment 100 by the distance m, and then the steps d and e are repeated in a circulating manner until the sliding beam 1 is retracted from the immersed tube segment 100 to the initial position of the second prefabricated area 5 area 102, and then the step f is performed. The retreating distance m of the sliding beam 1 from the immersed tube segment 100 is a segment length value of the immersed tube segment 100. The above-mentioned immersed tube segment 100 and the prefabricated means on the upper portion of the immersed tube segment 100 are moved together forward by a length l equal to the length of N-1 segments of the immersed tube segment 100.
It should be noted that the value of l should be several times of the unit segment length of the number N of the immersed tube segment 100 segments, and the comprehensive analysis is performed according to the specific segment number of the immersed tube segment 100, so as to ensure that the whole system can be balanced and stable when the prefabricated device at the upper part of the immersed tube segment 100 exits. For example, when n=3, the immersed tube segment 100 includes 3 segments, and then the value of the length l of the immersed tube segment 100 and the upper prefabrication device of the immersed tube segment 100 moved together toward the third region 103 in the step b is equal to the value of the segment length of 2 immersed tube segments 100, so that the overall system can be kept balanced and stable when the upper prefabrication device of the immersed tube segment 100 exits; when n=5, the immersed tube segment 100 includes 5 segments, and the value of the moving length l of the immersed tube segment 100 and the prefabricated device at the upper part of the immersed tube segment 100 towards the region three in the step b is not necessarily equal to the value of the segment length of 4 immersed tube segments 100, the value of the segment length of 3 immersed tube segments 100 can be adopted, and the whole system can be balanced and stable when the prefabricated device at the upper part of the immersed tube segment 100 is withdrawn; when N is other value, the same is true.
The pipe section 100 is lifted and transported by a lifting device 56 and a transporting device 55 arranged on the prefabricated site 5. The lifting device 56 and the transporting device 55 may adopt the structure in embodiment 2.
In the factory immersed tube prefabrication method according to embodiment 3, firstly, binding a bottom plate and a side wall reinforcement cage in a first area 101 of a prefabrication site 5, then moving the bottom plate and the side wall reinforcement cage to the lower part of an upper prefabrication device of an immersed tube joint 100 in a second area 102 of the prefabrication site 5, setting a side die 7 and a side die supporting frame 8, then binding a top plate reinforcement cage 92 by taking a sliding beam 1 and an inner die 2 of the upper prefabrication device of the immersed tube joint 100 as a platform, then performing concrete pouring, waiting for concrete pouring to form the immersed tube joint 100, and withdrawing the side die 7 and the upper prefabrication device of the immersed tube joint 100 from the immersed tube joint 100, thereby completing prefabrication of the immersed tube joint 100. The method divides the binding of the existing reinforcement cage into two parts, so that the first area 101 carries out the binding area of the bottom plate and side wall reinforcement cage 91, and the second area 102 carries out the binding of the top plate reinforcement cage 92; when the bound bottom plate and the bound side wall reinforcement cage are under the action of the lifting device 56 and the moving device 55, the bottom plate and the side wall reinforcement cage can "walk into" the prefabricating device at the upper part of the immersed tube joint 100, so that the equipment which is comparatively complex in arrangement, such as a bottom temporary lifting system, a reinforcement cage pushing system and the like, adopted by the template to "walk into" the reinforcement cage in the existing immersed tube prefabricating method can be eliminated, thereby greatly simplifying the complex process of equipment system conversion and being simple to operate; in addition, because the binding of the top plate reinforcement cage 92 and the binding of the bottom plate and the side wall reinforcement cage 91 can be realized, compared with the prefabrication of the existing immersed tube joint 100, the template can be moved into the reinforcement cage only after the whole binding of the bottom plate, the middle wall and the top plate is finished, and the concrete pouring method is adopted, the binding of the top plate reinforcement cage 92 and the concrete pouring can be realized, and the parallel flow operation is formed by the binding of the bottom plate and the side wall reinforcement cage 91, so that the construction time is saved, and the prefabrication efficiency can be further improved; furthermore, the device for prefabricating the upper part of the immersed tube segment 100 does not need a template trimming area, so that the tube segment prefabricating space is saved, the tube segment 100 prefabricating process is simplified, the prefabricating period of the immersed tube segment 100 is shortened, and the prefabricating efficiency of the immersed tube segment 100 is improved.
To sum up, the factory method immersed tube prefabrication method according to embodiment 3 simplifies the immersed tube prefabrication work flow, reduces the space required for immersed tube prefabrication, improves the immersed tube prefabrication efficiency and shortens the immersed tube prefabrication period, and embodiment 3 is suitable for the rapid prefabrication of single-hole or multi-hole immersed tube sections 100.
Example 4
In this embodiment 4, when the prefabrication of the first immersed tube segment 100 by the factory immersed tube prefabrication method in embodiment 3 is completed, the prefabricated first immersed tube segment 100 is moved to the outfitting area, which is the area three 103 of the prefabrication site 5, and then steps one to six in the factory immersed tube prefabrication method in embodiment 3 are repeated, and prefabrication of the second immersed tube segment 100 is performed until prefabrication of all immersed tube segments 100 is completed.
Specifically, after the bottom plate and the side wall reinforcement cage of the second step of the factory method immersed tube prefabrication method in the previous immersed tube segment 100 in the implementation of the factory method in the embodiment 3 are all moved from the first area 101 to the lower part of the prefabrication device of the upper part of the immersed tube segment 100 in the second area 102, the factory method immersed tube prefabrication method in the embodiment 3 can be implemented in the first area 101 to prefabricate the next immersed tube segment 100, that is, the bottom plate and the side wall reinforcement cage 91 of the next immersed tube segment 100 are bound in the first step, so that when the first area 101 of the prefabrication area 5 is subjected to the binding of the top plate reinforcement cage 92 and the concrete pouring, the second area 102 of the prefabrication area 5 is subjected to the binding of the bottom plate and the side wall reinforcement cage 91 of the second immersed tube segment 100, thereby forming the parallel flow synchronization operation of the immersed tube segments 100, further saving the construction time of the immersed tube segments 100, further improving the prefabrication efficiency of the immersed tube segments 100, and the embodiment 4 is suitable for the rapid prefabrication of the single-hole or multi-hole immersed tube segment 100.
Example 5
As shown in fig. 17 and fig. 17a-17y, in this embodiment 5, let the immersed tube segment 100 have a length l=60 m, a hole number b=1, and an immersed tube segment 100 segment segmentation number n=3 be taken as examples (i.e. the immersed tube segment 100 is divided into 3 segments by casting an inner mold 2, each segment 2 has a length of 20 m), and the flow of the immersed tube prefabrication method by the factory method according to the present invention is as follows:
1. initial state and numbering;
fig. 17 shows that the immersed tube prefabrication working step is an initial state, for convenience of description, the reinforcement cage segments, the inner mold segments, the supporting legs 13 and the tube segment segments are numbered, and the number of the reinforcement cage in the first 101 area of the prefabrication site 5 is assumed to be sequentially from left to right to be B1-B3, namely, the reinforcement cage segment one B1, the reinforcement cage segment two B2 and the reinforcement cage segment three B3; F1-F3 are sequentially numbered from left to right in the second region 102, namely, an inner mold segment F1, an inner mold segment II F2 and an inner mold segment III F3, and the support legs 13 of the sliding beam 1 are sequentially numbered from left to right as L1-L6, namely, a support leg I1, a support leg II L2, a support leg III L3, a support leg IV L4, a support leg V L5 and a support leg VI L6; the serial numbers of the pipe section 100 of the concrete immersed tube in the area III 103 are S1 to S3 in sequence, namely a first pipe section S1, a second pipe section S2 and a third pipe section S3; fig. 17a is an initial state diagram of a prefabricated immersed tube section 100 at a prefabricated site 5 by a factory method immersed tube prefabrication method.
2. The five support legs L5 and the six support legs L6 are completely lifted so that the reinforcement cage is ready to be moved from the first area 101 to the second area 102 before entering, as shown in figures 17b and 17 c;
3. the first reinforcement cage segment B1 is displaced into the first inner mold segment F1 as shown in fig. 17 d-17F;
(a) As shown in fig. 17d, a transfer device 55, such as a trolley, transfers the first reinforcement cage segment B1 to the third F3 position of the inner mold segment;
(b) As shown in fig. 17e, the six support legs L6 are put down, the three support legs L3 and the four support legs L4 are completely lifted, the first steel reinforcement cage section B1 is shifted forward by one section, and the steel reinforcement cage section B1 is moved to the second F2 position of the inner mold section;
(c) As shown in fig. 17F, the support leg five L5 is lowered, the support leg two L2 is fully lifted, and the first reinforcement cage segment B1 continues to shift forward one segment to the first inner mold segment F1 position;
it should be noted that: when the supporting legs 13 of the sliding beam 1 need to be lifted completely, the supporting legs 13 are lifted above the cross bars at the bottom of the inner mold supporting frame 3, so that the bottom plate, the side wall reinforcement cages 91 and the inner mold 2 can pass through the bottom positions of the supporting legs 13 smoothly.
4. The second reinforcement cage segment B2 is shifted into the second internal mold segment F2, as shown in fig. 17 g-17 h;
(a) As shown in fig. 17g, the third support leg L3 and the fourth support leg L4 are put down, the fifth support leg L5 and the sixth support leg L6 are completely lifted, and the second reinforcement cage segment B2 is shifted to the third F3 position of the inner mold segment;
(b) As shown in fig. 17h, the second support leg L2 and the sixth support leg L6 are put down, the third support leg L3 and the fourth support leg L4 are completely lifted, and the second reinforcement cage segment B2 is shifted to the second inner mold segment F2.
5. The reinforcement cage segment three B3 is displaced into the inner mold segment three F3 as shown in fig. 17 i.
The four support legs L4 are put down, the six support legs L6 are completely lifted, and the third steel reinforcement cage section B3 is shifted to the third inner mold section F3.
6. Changing the support legs to perform preparation before concrete pouring, and lifting the six L6 support legs in FIG. 17i to put down to prepare for preparation before pouring as shown in FIG. 17 j;
from the above described state of flow 1 to flow 6, the inner mould support frame 3 is in a contracted state, i.e. the inner mould 2 is also in a contracted state and is not in direct contact with the respective sections of the reinforcement cage, as shown in figures 17k,17k-1, 17 k-2.
7. The pipe section segment S1 is formed by casting concrete, as shown in figures 17l-17 n.
(a) 17L, 17L-1 and 17L-2, the side mold supporting frame 8 is moved to the first F1 position of the inner mold segment, binding of the top plate reinforcement cage 92 is carried out, and the three L3 supporting legs are put down, so that the first F1 position of the inner mold segment is bound with the top plate reinforcement cage 92, the load on the inner mold 2 is larger, more support can be provided by putting down the three L3 supporting legs, and the inner mold supporting frame 3 is still in a retracted state;
(b) As shown in fig. 17m, 17m-1, 17m-2, the inner mold support frame 3 of the inner mold segment one F1 is unfolded, i.e., the inner mold 2 is unfolded, the support legs two L2 are completely lifted, and the pouring work is ready to start;
(c) 17n, 17n-1 and 17n-2, pouring concrete at the first F1 position of the inner mould section to form the first S1 section of the pipe section, and binding a top plate reinforcement cage 92 at the third F3 position of the inner mould section;
(d) And (3) pouring concrete into the first steel reinforcement cage stage B1 to form a first pipe joint section S1.
It should be noted that: when the second area 102 is used for binding the top plate reinforcement cage 92 and pouring concrete, the first area 101 can be used for binding the bottom plate and the side wall reinforcement cage 91.
8. Concrete pouring pipe joint segment III S3 and pipe joint segment II S2 are shown in figures 17o-17p.
(a) 17o and 17o-1, supporting legs II L2 are supported on the inner wall of a first S1 of a cast-in-place immersed tube joint section of concrete, a third S3 of the cast-in-place tube joint section is carried out, and meanwhile, a top plate reinforcement cage 92 of a second S2 of the tube joint section is bound;
(b) 17p and 17p-1, supporting legs five L5 are supported on the inner wall of a cast immersed tube joint segment III S3, the supporting legs III L3 and four supporting legs L4 are completely lifted, and a tube joint segment II S2 is cast;
It should be noted that: in the present process, the first region 101 continues to bind the bottom plate and the side wall reinforcement cage 91 while the second region 102 performs concrete curing work of the poured immersed tube joint segment.
9. The immersed tube is displaced by each tube segment section, the inner die 2 and the sliding beam 1 are retracted, as shown in figures 17q-17x.
(a) As shown in fig. 17q, the third support leg L3 and the fourth support leg L4 are supported on the inner wall of the second immersed tube segment S2, the first support leg L1 and the sixth support leg L6 are completely lifted, and the immersed tube segment 100 is moved forward by a distance a of two tube segment lengths (i.e., the length of the first tube segment+the second tube segment) through the transport trolley;
(b) As shown in fig. 17r, all the supporting legs 13 of the sliding beam 1 are completely lifted and supported on the inner mold 2, at this time, the inner mold supporting frame 3 is unfolded, i.e. the inner mold 2 is unfolded and supported on the inner wall of the concrete immersed tube segment 100, and the sliding beam 1 is retracted by one segment length b; in fig. 17r, where the pipe joint segments are identical, b is equal to one half of a;
(c) As shown in fig. 17s, the six support legs L6 are put down, the first support leg L1 is supported on the inner wall of the immersed tube segment 100, the inner die 2 is contracted and supported on the sliding beam 1, the second inner die segment F2 and the third inner die segment F3 are simultaneously retracted by a distance equal to b in length of one tube segment;
(d) As shown in fig. 17t, three support legs L3 are supported on the inner wall of the immersed tube segment 100, the support leg L1 is completely lifted, the inner mold segment F1 is retracted by a distance equal to b in size;
(e) As shown in fig. 17u, the inner mold 2 is unfolded and supported on the inner wall of the immersed tube segment 100, and the supporting leg 13 of the sliding beam 1 is lifted up entirely and retracted by the inner mold by a distance of one segment length, the distance being equal to b;
(f) As shown in fig. 17v, the six support legs L6 are put down, the first support leg L1 is supported on the inner wall of the immersed tube segment 100, the second inner mold segment F2 and the third inner mold segment F3 shrink and retract by the force sliding beam 1 by a distance equal to b;
(g) As shown in fig. 17w, three support legs L3 and four support legs L4 are put down, the first support leg L1 is lifted up, the first inner mold segment F1 is contracted and retracted by the force sliding beam 1 by a distance equal to b in size of one pipe joint segment length;
(h) As shown in fig. 17x, the transfer device 55 transfers the immersed tube segment 100 to the outfitting area, and complete demolding of the immersed tube segment 100 from the inner mould 2 is achieved.
10. As shown in fig. 17y, the production cycle of one immersed tube segment 100 is completed, the initial state shown in fig. 17a is returned, and the prefabrication of the next immersed tube segment 100 is performed.
The factory method immersed tube prefabrication method of the embodiment 5 achieves the effects of simplifying the immersed tube prefabrication work flow, reducing the space required by immersed tube prefabrication, improving the immersed tube prefabrication efficiency and shortening the immersed tube prefabrication period. Test comparison shows that aiming at a immersed tube section 100 with the length of 180m and the weight of about 7 ten thousand tons, a single assembly line of a conventional factory immersed tube prefabrication assembly line is adopted, the immersed tube section 100 can be prefabricated only in 60 days, and the immersed tube section 100 can be prefabricated only in 15-20 days by adopting the single assembly line of the method, so that the prefabrication efficiency is greatly improved.
The above description is only of the preferred embodiments of the present invention, and is not intended to limit the present invention, but any modifications, equivalent substitutions and improvements made within the spirit and scope of the present invention should be included in the scope of the present invention.

Claims (37)

1. A factory method immersed tube prefabrication method is characterized in that a factory method immersed tube prefabrication system is adopted, and the prefabrication system comprises a first area and a second area;
the first area is a binding area of the bottom plate and the side wall reinforcement cage;
the second area is a binding area of a top plate reinforcement cage and a concrete pouring area, the second area comprises a bottom die arranged on a prefabricated site, a prefabricated device at the upper part of a immersed tube joint is arranged on the bottom die, the prefabricated device at the upper part of the immersed tube joint comprises a sliding beam, the sliding beam comprises a bracket and a plurality of telescopic supporting legs arranged on the bracket, an inner die supporting frame capable of longitudinally sliding relative to the bracket is arranged on the bracket, an inner die is sleeved outside the inner die supporting frame, an opening and closing device capable of expanding or contracting the inner die is further arranged on the inner die supporting frame, side dies are respectively arranged at two sides of the inner die, each side die comprises a side die panel, and a side die supporting frame is arranged outside each side die panel; the length of the sliding beam exceeds the length of the inner die, and supporting legs are respectively arranged at two ends of the sliding beam, so that the inner die can be arranged between the two supporting legs at the end part of the sliding beam;
The prefabricated site is further provided with a lifting device and a transporting device, the lifting device is used for lifting the bottom plate and the side wall reinforcement cage up and down, and the transporting device is used for transporting the bottom plate and the side wall reinforcement cage from the first area to the lower part of the inner mold of the second area;
the immersed tube prefabrication step comprises the following steps:
binding the bottom plate and the side wall reinforcement cage in a first prefabricated field area;
moving the bottom plate and the side wall reinforcement cage to the position below the prefabricated device at the upper part of the immersed tube joint, and moving the bound bottom plate and side wall reinforcement cage from the first region to the second region, wherein the bottom plate and the side wall reinforcement cage are positioned below the sliding beam and the inner die and above the bottom die, and the inner die is in a contracted state;
setting side dies, wherein the side dies and side die supporting frames thereof are respectively arranged on two sides of the bottom plate and the side wall reinforcement cage;
binding a top plate reinforcement cage, binding the top plate reinforcement cage above the immersed tube pipe joint upper prefabrication device, and connecting the top plate reinforcement cage, the bottom plate and the side wall reinforcement cage with each other to form an integral tube joint reinforcement cage;
Fifthly, pouring concrete, namely expanding an inner die of the prefabricated device at the upper part of the immersed tube section, and performing concrete pouring to form the immersed tube section;
step six, withdrawing the side mould and the immersed tube section upper prefabricating device, wherein the side mould supporting frame drives the side mould to withdraw from the side surface of the immersed tube section, the inner mould of the immersed tube section upper prefabricating device contracts, and the sliding beam and the inner mould withdraw from the inside of the immersed tube section to finish prefabricating the immersed tube section.
2. A factory-process immersed tube prefabrication method according to claim 1, wherein the inner mould and inner mould support frame each comprise N segments in the longitudinal direction, the length of the inner mould segments being adapted to the length of the inner mould support frame segments, wherein N is ≡1.
3. A factory-process immersed tube prefabrication method according to claim 2, wherein the skid beam comprises the same number of skid beam sections as the inner mould support frame sections, the lengths of the skid beam sections being adapted to the inner mould support frame sections, each skid beam section being provided with at least two of the support legs.
4. A factory-process immersed tube prefabrication method according to claim 3, wherein all the skid beam sections are interconnected into a unitary structure, and wherein all the inner mould sections and inner mould support frame sections are each capable of being slidably disposed on the skid beam independently.
5. A factory-process immersed tube prefabrication method according to claim 2, wherein the inner mould and the inner mould supporting frame each comprise at least three segments, N being equal to or greater than 3, wherein the segments are of equal length.
6. A factory-method immersed tube prefabrication method according to claim 1, wherein each of the support legs is provided with a telescopic means which enables it to be extended and retracted up and down, or with a folding means which enables it to be folded.
7. A factory-process immersed tube prefabrication method according to claim 1, wherein a longitudinal displacement means is provided between the support and the inner mould supporting frame to enable the support and the inner mould supporting frame to slide longitudinally relative to each other.
8. The method for prefabricating a factory-method immersed tube according to claim 7, wherein the longitudinal moving means is a plurality of jacks connected between the support and the inner mould supporting frame, and tank wheels are slidably connected between the support and the inner mould supporting frame.
9. The factory-method immersed tube prefabrication method according to claim 1, wherein a supporting cross rod is arranged at the upper end of each supporting leg, sliding rails are longitudinally arranged on all the supporting cross rods along the sliding beam, inverted-U-shaped sliding grooves are formed in the inner die supporting frame, and the sliding rails can slide on the inverted-U-shaped sliding grooves.
10. The factory-method immersed tube prefabrication method according to claim 1, wherein the inner mould supporting frame comprises a left supporting frame and a right supporting frame, the top ends of the left supporting frame and the right supporting frame are hinged to each other, the bottoms of the left supporting frame and the right supporting frame are hinged with a telescopic supporting beam, the supporting beam is provided with an opening and closing device, and the opening and closing device is a jack.
11. A factory method immersed tube prefabrication method according to claim 10, wherein the inner mould is fixed to the inner mould support frame by bolts or hoops or welding.
12. The method for prefabricating a submerged arc tube according to claim 10, wherein the inner mould comprises an inner mould top plate and inner mould side plates arranged at two sides of the inner mould top plate.
13. The method for prefabricating a factory-method immersed tube according to claim 12, wherein stiffening angle steel I distributed along the longitudinal direction is arranged on one surface of the inner die top plate and one surface of the inner die side plate opposite to the inner die supporting frame.
14. The factory-method immersed tube prefabrication method according to claim 1, wherein the inner side of the side mould panel is further provided with a plurality of split bolts for connecting to the bottom plate and the side wall reinforcement cage.
15. The factory-method immersed tube prefabrication method according to claim 1, wherein a plurality of second stiffening angle steel are arranged on the outer side of the side mould panel.
16. A factory-process immersed tube prefabrication method according to claim 1, wherein the side forms are fixed to the side form support frame by bolts or hoops or welding.
17. A factory-method immersed tube prefabrication method according to claim 1, wherein the side mould supporting frame is provided with a plurality of universal wheels at the bottom.
18. A factory-process immersed tube prefabrication method according to claim 1, wherein the counter die is fixedly connected to the prefabrication site.
19. A factory method immersed tube prefabrication method according to any of claims 1-18, wherein the transporting means comprises at least one set of track grooves respectively provided on the prefabrication site, each set of track grooves comprises two track grooves, a track is provided in each track groove, and a plurality of trolleys are slidably provided on the track.
20. A factory method immersed tube prefabrication method according to claim 19, wherein the lifting means comprises a jack provided on each trolley.
21. The method for prefabricating a factory-process immersed tube according to claim 19, wherein a step is provided above the track groove, the step is covered with a movable plate, and when the movable plate is mounted on the step, the upper surface of the movable plate is flush with the upper surface of the bottom die.
22. A factory method pipe-sinking prefabrication method according to claim 19, wherein the prefabrication site further comprises a third zone which is an outfitting zone for prefabrication of pipe sections of pipe.
23. The method for prefabricating a factory-method immersed tube according to claim 1, wherein the bottom plate and the side wall reinforcement cage in the first step are bound in sections in the first area of the prefabrication site.
24. The method for prefabricating the immersed tube by a factory method according to claim 23, wherein after the bottom plate and the side wall reinforcement cage are all moved below the prefabricating device on the upper portion of the immersed tube, the side dies and the side die supporting frames thereof are sequentially arranged on the subsections, the top plate reinforcement cage is bound, the immersed tube section is formed by concrete pouring, the next section of the immersed tube section is formed, and prefabrication of the whole immersed tube section is finally completed.
25. The factory-method immersed tube prefabrication method according to claim 24, wherein when the immersed tube segments are concreted, concrete pouring is respectively carried out according to the interval sequence of the segments, and the immersed tube segment segments are sequentially formed.
26. A factory-process immersed tube prefabrication method according to claim 1, wherein the immersed tube joint segments are 20-50m in length.
27. A factory method immersed tube prefabrication method according to claim 1, wherein in carrying out the third and/or fourth steps, the support legs at the two ends of the sliding beam of the prefabricated device at the upper part of the immersed tube section are extended and supported on the prefabrication site, and the other support legs between the support legs at the two ends of the sliding beam are partially extended or fully extended to pass through the bottom plate and the side wall reinforcement cage to be supported on the bottom die.
28. The method for prefabricating a submerged pipe according to claim 1, wherein in the fifth step, when the concrete is poured, the support legs of the sliding beam positioned in the concrete pouring area are retracted and lifted, and the support legs positioned at the two ends of the sliding beam are extended and supported on the prefabrication site.
29. The factory method immersed tube prefabrication method according to claim 1, wherein in the fifth step, when the immersed tube segments are concreted in sections, supporting legs of the sliding beams in the concreting areas of the sections are contracted and lifted, supporting legs of the sliding beams in the concreting areas of the non-concreting sections are stretched and supported on a bottom die, supporting legs in the poured immersed tube segments are contracted and lifted or stretched and supported on inner walls of the poured immersed tube segments, and supporting legs at two ends of the sliding beams are stretched and supported on a prefabrication site.
30. A factory method according to claim 22, wherein in step six, when the upper prefabricating device of the immersed tube section is withdrawn, the side mould supporting frame drives the side mould to withdraw from the side of the immersed tube section, then the immersed tube section and the upper prefabricating device of the immersed tube section are moved towards the area three by a length l together, then the upper prefabricating device of the immersed tube section is retracted from the inside of the immersed tube section to a position of the prefabricating area one, and finally the immersed tube section is removed, wherein l is smaller than the length of the immersed tube section.
31. A factory method pipe-sinking process according to claim 30, wherein when the pipe section comprises N segments, the concrete steps of withdrawing the apparatus for prefabricating the upper part of the pipe section are:
step a, supporting legs at two ends of a sliding beam of a prefabricated device at the upper part of the immersed tube section are contracted and lifted, and the supporting legs of the sliding beam positioned in the immersed tube section are stretched and supported on the inner wall of the immersed tube section;
b, moving the immersed tube joint and the immersed tube joint upper prefabrication device together towards the direction of a third area by a length l; c, expanding an inner die of the prefabricated device at the upper part of the immersed tube joint through an opening and closing device supported by an inner die supporting frame, supporting the inner die on the inner wall of the immersed tube joint, and shrinking and lifting all supporting legs of the sliding beam;
D, keeping the immersed tube section, the inner die and the inner die supporting frame fixed, backing the sliding beam from the immersed tube section to a prefabricated site, and extending supporting legs of the sliding beam outside the immersed tube section and supporting the prefabricated site;
step e, contracting the inner mold supporting frame to drive the inner mold to be folded and contracted, wherein the inner mold supporting frame drives the inner mold to retract from the immersed tube section along the sliding beam;
and f, removing the immersed tube section until the sliding beam and the internal mold of the immersed tube section upper prefabricating device are all retracted from the immersed tube section, thereby completing the prefabrication of the immersed tube section.
32. The factory-method immersed tube prefabrication method according to claim 31, wherein when step d is performed, if the sliding beam cannot be retracted from the immersed tube section to the prefabrication area two initial positions at one time, after the sliding beam is retracted from the immersed tube section by a distance m, step e is performed, and then steps d and e are repeated in a circulating manner until the sliding beam is retracted from the immersed tube section to the prefabrication area two initial positions, and step f is performed.
33. A factory method immersed tube prefabrication method according to claim 32, wherein the retreating distance m of the slipping beam from the immersed tube section is a section length value of the immersed tube section.
34. A factory method immersed tube prefabrication method according to claim 31, wherein the immersed tube segments and the immersed tube segment upper prefabrication means are moved together forwards by a length l equal to the length of N-1 segments of the immersed tube segments.
35. The factory method immersed tube prefabrication method according to claim 1, wherein the immersed tube joint is lifted and transported by a lifting device and a transporting device arranged on a prefabrication site respectively.
36. A factory method pipe-sinking prefabrication method according to any one of claims 21 to 35, wherein after step six is carried out, the prefabricated pipe-sinking section is transported to the third outfitting area of the prefabrication site, and then steps one to six are repeated to prefabricate the next pipe-sinking section.
37. A factory method according to claim 36, wherein after the last immersed tube section is below the apparatus for prefabricating the upper portion of the immersed tube section in which the floor and side wall reinforcement cages in step two are moved from zone one to zone two, step one is performed in prefabrication site zone one for floor and side wall reinforcement cage ligations for the next immersed tube section.
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CN103726511B (en) * 2013-11-29 2016-02-03 中交第四航务工程局有限公司 A kind of template system for large-area tunnel immersed tube monobloc cast
CN103696441B (en) * 2013-11-29 2015-12-30 中交第四航务工程局有限公司 The method that automatic hydraulic steel form group and immersed tube tube coupling are built
DK2910687T3 (en) * 2014-02-25 2017-01-16 Doka Gmbh Apparatus and method for making one of several tunnel sections constructed
WO2017166160A1 (en) * 2016-03-31 2017-10-05 中交第二航务工程局有限公司 Short-line match-casting-based precast template system for girder bridge having composite structure and corrugated steel webs
CN109680720B (en) * 2019-01-14 2021-02-26 中交第二航务工程局有限公司 Construction method for continuously prefabricating dry dock immersed tube segment
CN210758338U (en) * 2019-08-13 2020-06-16 中交第四航务工程局有限公司 Immersed tube tunnel internal mold system
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