CN116277467A - Dry dock system for prefabricating immersed tube tunnel in assembly line and prefabricating method of dry dock system - Google Patents

Abstract

The invention relates to the technical field of immersed tube tunnel construction, in particular to a dry dock system for prefabricating an immersed tube tunnel in a production line and a prefabricating method thereof.

Description

Dry dock system for prefabricating immersed tube tunnel in assembly line and prefabricating method of dry dock system

Technical Field

The invention relates to the technical field of immersed tube tunnel construction, in particular to a dry dock system for prefabricating an immersed tube tunnel in a production line and a prefabricating method thereof.

Background

The existing immersed tube prefabrication method mostly adopts a dry dock method and a factory method. The prefabricated site of the dry dock method mainly comprises a dock area and a dock gate, the prefabrication of the immersed tube is directly carried out on the ground of the dock bottom, after the prefabrication is finished, the immersed tube is enabled to be consistent with the external sea level by pouring water into the dock area, so that the immersed tube floats, and then the dock gate is opened to be undocked. Because the immersed tube prefabrication and the floating transportation of the dry dock method are in one dock area, the prefabrication and the floating transportation cannot be carried out simultaneously, flow operation cannot be formed, the construction period pressure is high, the prefabrication of a batch of tube sections generally needs 8-11 months, and the immersed tube sections are greatly influenced by factors such as places, weather and the like and have long construction period; the existing dry dock method is directly prefabricated on the ground of the dock bottom, no bottom mould exists, the bottom of the immersed tube is a hidden project, the bottom quality of the immersed tube is difficult to ensure when the immersed tube is poured, a waterproof bottom steel plate is arranged at the bottom for preventing leakage, and the complex polyurea packaging technology is manufactured on the appearance, so that the dry dock method is economical and expensive.

The existing factory method has the advantages of high prefabrication speed, good quality, good risk management and control, and capability of recycling factories, but large places are needed, large factories, shallow docks and deep docks are needed to be built, or a dock and a bottom harbor pool are needed to be built, semi-submerged barges are arranged, and the like, so that the prefabrication, the launching and the shipment of immersed tubes can be met. Specifically, a method for carrying out pipeline operation is provided by a patent document with the application number of CN201310633846.4, carrying out the working procedures of processing, binding and pouring reinforcing steel bars in a pipeline manner in a prefabrication workshop, arranging a lower water dock (a combination of a shallow dock and a deep dock) close to the prefabrication workshop, opening a shallow dock door after prefabrication of the immersed tube, conveying the immersed tube to the shallow dock area for primary outfitting, closing the shallow dock door after outfitting, filling water into the dock pool until the immersed tube floats, thereby directly pulling the immersed tube from the shallow dock area to the deep dock area, then draining water to enable the shallow dock area to meet the dry construction condition for outfitting construction of the next pipe section, carrying out primary outfitting on the immersed tube in the shallow dock area while carrying out secondary outfitting on the immersed tube in the deep dock area, opening the deep dock door after the secondary outfitting is completed, and pulling the immersed tube out of the dock under the action of water buoyancy. Another way to prefabricate a reinforced concrete caisson is to complete the outfitting process in the prefabrication shop and then to transfer the caisson to the loading dock by means of a trolley mechanism or crane, etc., for transport by semi-submersible barges. Although the factory method has the advantage of short construction period due to pipeline operation, the method is limited by sites and economy, the sites need to be found far away from tunnel sites, the problems that the temporary construction sites are difficult to find or the transportation distance is long often exist, the temporary construction cost and the transportation cost are high, the space size of shallow docks and deep docks cannot be simultaneously met due to the limited site scale, and the method cannot be implemented under the condition of not meeting the transportation with semi-submerged docks. Therefore, for the construction of the above-mentioned situations, especially in the inland river, city river-crossing areas with small space and large limitation, it is necessary to propose a new construction method to adapt to the site construction conditions.

Disclosure of Invention

The invention aims at: aiming at the problems that in the prior art, shallow docks and deep docks are needed to be built in the process of prefabricating immersed tubes by a factory method, the immersed tubes are required to be transported by floating, the required sites are large in scale, or a transport dock and a sitting bottom harbor pool are needed to be built, the immersed tubes are transported by a semi-submerged transport mode, the requirements on the construction conditions of the temporary sites are high, and the method is not suitable for construction in areas with small space, the dry dock system and the prefabricating method of the pipeline prefabricated immersed tube tunnel are provided, and can be compatible with contradictions between site scale limitation and construction period.

In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:

the prefabrication method based on prefabricated immersed tube tunnel of dry dock system assembly line, dry dock system includes reinforcing bar ligature dock and outfitting dock of intercommunication, wherein is equipped with reinforcing bar ligature district and pouring district in the reinforcing bar ligature dock, is equipped with interior dock gate between reinforcing bar ligature dock and the outfitting dock and is used for the break-make, and the face side of outfitting dock is equipped with outer dock gate and is used for the break-make, includes following steps during the construction:

step one, prefabricating a immersed tube reinforcement cage in a reinforcement binding area;

step two, transferring the reinforcement cage to a pouring area for pouring operation;

transferring the immersed tube after pouring to an outfitting dock for one-time outfitting operation;

closing an inner dock gate, and irrigating water into the outfitting dock to float the immersed tube;

and fifthly, opening an outer dock gate, and removing the immersed tube from the dock.

According to the invention, the reinforcement binding procedure, the pouring procedure and the outfitting procedure in the immersed tube prefabrication process are synchronously constructed in different areas, so that the immersed tube prefabrication can be quickly completed by forming assembly line operation, and the prefabrication period is short; according to the invention, the outfitting is carried out once after the pouring process is finished, the outfitting dock can be undocked after being irrigated and floated, compared with the mode that the shallow dock is required to be transitionally undocked from the deep dock to the deep dock for prefabricating the immersed tube by the traditional factory method, the method shortens the operation assembly line under the same prefabrication efficiency, has the advantages of small construction engineering quantity of the outfitting dock, small occupation of the prefabrication site, and reduced construction difficulty and investment cost. The primary outfitting of the immersed tube mainly comprises a series of temporary auxiliary facility installation work which is needed to be performed before the immersed tube floats, wherein the temporary auxiliary facility installation work comprises a ballast water tank, a ballast water pipeline, a ballast water pump, temporary ventilation, illumination, an end sealing door and the like, and is used for guaranteeing the tightness of the immersed tube in the floating installation process.

The invention improves the traditional factory method, reduces the field scale under the same prefabrication efficiency, is not limited by ship finding and wharf, has low requirements on the construction conditions of the temporary construction field, can meet the construction conditions of the dry dock field near the tunnel site, thereby reducing the transportation cost and being applicable to the construction of the area with smaller space.

Preferably, a pushing device is adopted to push the reinforcement cage from the reinforcement binding area to the pouring area along the displacement track, wherein a bottom jig frame is arranged below the reinforcement cage, a loading trolley is fixedly arranged below the bottom jig frame, and the loading trolley can roll along the displacement track, so that friction force is reduced; and lifting the reinforcement cage through a gantry crane at a station of the pouring area, dragging the bottom jig frame out, and returning the reinforcement cage to the reinforcement binding area, so that the reinforcement cage can be borne on a bottom die of a pouring pedestal for pouring. According to the invention, the reinforcement cage is transferred to the pouring area along the displacement track under the carrying of the loading trolley in a pushing mode, so that the pushing resistance is small, the carrying cost is low, the efficiency is high, and the using number and the cost of the trolley are saved.

Preferably, the immersed tube is transferred from the pouring area to the outfitting dock by means of a displacement trolley with lifting function, the immersed tube is transferred in the outfitting dock to be supported on the outfitting pedestal, and then the displacement trolley is withdrawn back to the pouring area for reuse.

Preferably, after one outfitting operation is completed, the gantry crane and the outfitting equipment in the outfitting dock are moved out of the outfitting dock and returned to the steel bar binding dock, and then the inner dock gate is closed, so that the construction gantry crane and the outfitting equipment are ensured to be in a water-free area.

Further, the construction step further includes a step six: after the immersed tube is undocked, closing an outer dock gate, and draining the outfitting dock so as to clean the outfitting dock; and then opening an inner dock gate, and transferring the next poured immersed tube section to an outfitting dock so as to circularly outfit the next tube section.

Preferably, the dry dock system is constructed by adopting an axial dry dock, and the position of an outer dock gate is set corresponding to the spatial position of a final joint of the immersed tube foundation trench. The axis dry dock construction is that the dry dock site for prefabricating pipe joints is constructed based on tunnel addresses, and the axis dry dock construction and the immersed tube foundation trench share the excavation section, so that occupation of construction sites and immersed tube transportation distance can be further reduced, engineering cost is low, and final joint construction of immersed tubes is facilitated.

Preferably, the outfitting dock is used as an outfitting area, and the reinforcement binding area, the pouring area and the outfitting area are sequentially arranged, so that the immersed tube prefabrication efficiency is improved, and the factory arrangement is simplified.

The invention further provides a dry dock system for implementing the prefabrication method, which comprises a steel bar binding dock, an outfitting dock and a secondary outfitting area, wherein the steel bar binding dock is internally provided with a steel bar binding area and a pouring area, the steel bar binding dock is communicated with the outfitting dock, an inner dock gate is arranged between the steel bar binding dock and the outfitting dock for on-off, an outer dock gate is arranged on the water facing side of the outfitting dock for on-off, the outfitting dock is positioned at a land buried section for constructing a tunnel, and the secondary outfitting area is positioned at an open section of a foundation trench in water adjacent to the land buried section. The dry dock system is adopted to prefabricate the immersed tube, the required site scale is small, the immersed tube prefabricating period is short, the quality is controllable, the regional dredging cost of transportation channels, deposit, convolution and the like is reduced, and the construction cost of the temporary construction site is reduced.

The invention also provides a prefabrication method for prefabricating the immersed tube tunnel based on the assembly line of the dry dock system, wherein the dry dock system comprises an outfitting dock, a pouring pedestal is arranged in the outfitting dock, an external dock gate is arranged between the outfitting dock and a water area for on-off, and the method comprises the following steps of:

step 1, transferring a prefabricated reinforcement cage to a pouring pedestal for pouring operation;

step 2, after the immersed tube pouring is completed, continuously performing one-time outfitting operation on the immersed tube on the pouring pedestal;

step 3, after the outfitting operation is completed, water is filled into the outfitting dock to enable the immersed tube to float;

and 4, opening an external dock gate, removing the immersed tube from the dock, and performing secondary outfitting.

According to the invention, the steel bar binding, pouring and outfitting procedures in the immersed tube prefabricating process are divided into two stations for synchronous construction, the pouring procedure and the outfitting procedure are arranged at the same station, the pouring operation is finished at the same station, then the outfitting operation is carried out, after the outfitting is finished once, the immersed tube floats to be undocked by pouring water into the outfitting dock, the immersed tube is not limited by ship searching and wharf, the prefabricating period is short, the prefabricating site scale is reduced, the method is suitable for construction in areas with smaller space, and the construction difficulty and investment cost are reduced. The procedure of prefabricating the reinforcement cage can be carried out in a dry dock or outside the dock, and the procedure is selected according to specific site construction conditions.

Based on this, as a preferred scheme, set up prefabricated steel reinforcement cage's reinforcement ligature district outside the dock, adopt the portal crane to transfer the steel reinforcement cage to pouring on the pedestal through the hoist and mount mode. According to the scheme, the dry dock system adopts a single dock mode, the engineering quantity of excavation and cofferdam is small, the occupied area is small, and the later backfill engineering quantity is reduced correspondingly.

Or as another preferable scheme, the dry dock system further comprises a steel bar binding dock, namely the dry dock system adopts a double-dock system, the steel bar binding dock is used as a steel bar binding area, the steel bar binding dock is communicated with an outfitting dock, and an inner dock gate is arranged between the steel bar binding dock and the outfitting dock for on-off; when transferring the steel reinforcement cage, adopt thrustor to push the steel reinforcement cage along the track of shifting to the pouring pedestal of outfitting dock, wherein be equipped with the bed-jig below the steel reinforcement cage, install the load dolly in the bed-jig below, the load dolly can roll along the track of shifting and move. The immersed tube finishes pouring operation on the pouring pedestal firstly, and then performs outfitting operation; after one-time outfitting is completed, returning the outfitting gantry crane and the outfitting equipment to the steel bar binding dock, closing an inner dock gate, then pouring water into the outfitting dock to float the immersed tube, opening an outer dock gate, and moving the immersed tube out of the dock; and closing the outer dock gate after undocking to drain and clean the outfitting dock, opening the inner dock gate, pushing the next reinforcement cage from the reinforcement binding area to a pouring pedestal of the outfitting dock, and performing immersed tube pouring and outfitting operation in a circulating manner.

Correspondingly, based on the prefabrication method, the invention also provides a dry dock system for implementing the prefabrication method, wherein the dry dock system comprises a land hidden buried section for constructing a tunnel and an open section of a water foundation trench adjacent to the land hidden buried section, a dry dock is arranged on the land hidden buried section, and a secondary outfitting area is arranged on the open section of the water foundation trench; the dry dock is used for carrying out pouring operation and one outfitting operation, and the pouring operation and the one outfitting operation are located at the same station. The dry dock system is adopted to prefabricate the immersed tube, the required site scale is small, the immersed tube prefabricating period is short, the quality is controllable, the immersed tube transportation dredging cost is reduced, and the construction cost of the temporary construction site and the backfilling workload in the later period are reduced.

In summary, due to the adoption of the technical scheme, the beneficial effects of the invention are as follows:

1. the dry dock system and the prefabricating method thereof provided by the invention have the advantages of short prefabricating period, small required site scale and low cost, are not limited by semi-submerged barges and wharfs, reduce the addressing difficulty of temporary construction sites, and are suitable for construction in areas with smaller space.

2. The dry dock system and the prefabricating method thereof provided by the invention can be used for conditionally constructing based on tunnel addresses, and combine a pipe joint prefabricating site with a tunnel shore section, namely, the dry dock and the tunnel shore section share a part of foundation pit excavation and support, so that occupation and part of engineering cost of the construction site are reduced, and the prefabricated pipe fitting can be directly longitudinally floating and installed along a tunnel foundation trench in water after being pulled out of the dock, thereby reducing channel dredging cost.

3. The invention adopts the improved factory method to prefabricate the immersed tube in the dry dock, compared with the dry dock method, the invention solves the problem that the bottom of the dry dock bottom prefabricate the immersed tube is a hidden project, avoids the process of arranging a waterproof bottom steel plate at the bottom of the immersed tube, and simultaneously solves the problem of long period of prefabricating the immersed tube compared with the traditional dry dock.

Drawings

FIG. 1 is a top view of a prefabricated sink pipe of the dry dock system pipeline of example 1;

fig. 2 is a floor plan view of a dock floor of the dry dock system of embodiment 1;

FIG. 3 is a middle longitudinal section view (with the door hanger apparatus omitted) at A1-A1 in FIG. 1;

FIG. 4 is an enlarged view at C1 in FIG. 3;

FIG. 5 is an enlarged view at C2 in FIG. 3;

FIG. 6 is a longitudinal section of A2-A2 of FIG. 1;

FIG. 7 is a cross-sectional view of B1-B1 of FIG. 1;

fig. 8 is a schematic structural view of the small-load vehicle-mounted steel reinforcement cage at C3 in fig. 7;

FIG. 9 is a cross-sectional view of B2-B2 of FIG. 1;

FIG. 10 is an enlarged view at C4 of FIG. 9;

fig. 11 is a cross-sectional view of B3-B3 of fig. 1 (cross-sectional view of the inner dock area);

FIG. 12 is a cross-sectional view of B4-B4 of FIG. 1 (cross-sectional view of the outfitting area);

FIG. 13 is an enlarged view at C5 of FIG. 12;

fig. 14 is a cross-sectional view of B5-B5 of fig. 1 (cross-sectional view of the outer dock section);

FIG. 15 is a top view of a prefabricated sink pipe of the dry dock system pipeline of example 2;

FIG. 16 is a longitudinal section view of A3-A3 of FIG. 15;

FIG. 17 is a cross-sectional view of B6-B6 of FIG. 15;

FIG. 18 is a top view of a prefabricated sink pipe of the dry dock system pipeline of example 3;

FIG. 19 is a longitudinal cross-sectional view of A4-A4 of FIG. 18;

fig. 20 is a cross-sectional view of B7-B7 of fig. 18.

Icon: 10-a steel bar processing plant,

20-reinforcing steel bar binding dock, 21-dock top ground, 22-lower dock channel, 23-dock bottom ditch, 24-dry dock waterproof curtain,

30-reinforcing steel bar binding area, 31-factory door crane, 311-crane, 32-factory track, 33-reinforcing steel bar cage, 34-shift track, 35-bottom jig frame, 351-loading trolley, 36-pushing device,

40-pouring area, 41-second door crane, 411-second crane, 42-second factory track, 43-first track beam, 431-trolley track, 44-track Liang Er, 45-bottom die, 46-inner die, 47-outer die, 48-concrete pouring machine, 481-pump pipe,

50-inner dock area, 51-inner dock block, 52-inner dock gate, 53-inner dock gate bottom plate,

60-outfitting dock, 61-factory door crane III, 62-factory track III, 63-passive support, 64-shift trolley,

70-outer dock area, 71-outer dock block, 72-outer dock gate, 73-outer dock gate bottom plate,

80-secondary outfitting area, 81-immersed tube,

90-buttress.

Detailed Description

The present invention will be described in detail with reference to the accompanying drawings.

The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.

Example 1

The embodiment provides a dry dock system for prefabricating a immersed tube tunnel in a production line and a prefabricating method thereof. The dry dock system in the embodiment fully utilizes the economic advantages of the axis dry dock, uses the foundation grooves of the land buried section and the open section of the tunnel to make the dry dock, uses the foundation grooves of the immersed tube to make the transportation channel and the secondary outfitting area, can avoid the problems of long-distance floating transportation of the immersed tube and the need of additionally arranging the secondary outfitting area or the convolution area, and simultaneously fully utilizes the operation space of the final joint as the operation space of the dock gate, thereby avoiding the problems of secondary weir building and long water stopping time after the final immersed tube is installed by adopting the axis dry dock method.

The dry dock system in this embodiment specifically adopts a double-dock system with inner and outer serial connection, as shown in fig. 1-14, and includes a steel bar processing factory 10, a steel bar binding dock 20, an inner dock entrance area 50, an outfitting dock 60, an outer dock entrance area 70 and a secondary outfitting area 80, the steel bar processing factory 10 is arranged on the ground 21 of the dock roof, a dry dock waterproof curtain 24 is further arranged under the vertical and vertical direction of the dock roof, the dry dock area on the land side is surrounded, and surrounding underground water is blocked from flowing into the dock; a dock bottom ditch 23 is arranged along the dock bottom edges of the steel bar binding dock 20 and the outfitting dock 60 for dry dock drainage, wherein the steel bar binding dock 20 is used for steel bar binding, equipment system conversion and concrete pouring, and the outfitting dock 60 is used for primary outfitting of pipe joints and floating of the pipe joints; accordingly, the reinforcement bar tie-up dock 20 is located at the land end, the internal dock, and the outfitting dock 60 is located adjacent to the water side, the external dock. A reinforcement binding area 30 and a pouring area 40 are sequentially arranged in the reinforcement binding dock 20; a binding pedestal is arranged corresponding to the steel bar binding area 30, and a factory building gantry crane 31 and a crane 311 are arranged above the binding pedestal for hoisting operation; a pouring pedestal is arranged corresponding to the pouring area 40, a second factory door crane 41 and a second crane 411 are arranged above the pouring pedestal, and a concrete pouring machine 48, a pump pipe 481 and other devices are correspondingly installed for pouring operation; an outfitting pedestal is arranged in the outfitting dock 60, and a factory door crane III 61 and related outfitting equipment are arranged above the corresponding outfitting pedestal for outfitting operation; the construction of the prefabricated process of the current immersed tube 81 in the corresponding functional area is carried out by the binding pedestal, the pouring pedestal and the outfitting pedestal respectively, as shown in fig. 3 and 5, working surfaces of the binding pedestal, the pouring pedestal and the outfitting pedestal are all arranged at the same elevation, and the elevations of the floors of the pouring pedestal and the outfitting pedestal are lower than those of the floors of the binding pedestal, so that the construction operation under the pouring pedestal and the outfitting pedestal is convenient, the construction between the binding pedestals is carried out in a space above the working surface of the pedestal, after the immersed tube reinforcement cage 33 in the binding area is prefabricated, the immersed tube reinforcement cage 33 can be stably pushed onto the pouring pedestal on the same plane of each pedestal, and the conversion of a supporting system is completed. An inner dock block 51 and an inner dock gate 52 are arranged at the inner dock gate area 50, the inner dock gate area 50 is positioned between the steel bar binding dock 20 and the outfitting dock 60 and is used for isolating the two dock areas, the on-off effect is achieved, water is prevented from entering the steel bar binding dock 20 when water is poured into the outfitting area, the inner dock gate bottom plate 53 is used as a dock bottom foundation of the inner dock gate area 50, and the elevation of the inner dock gate bottom foundation is consistent with the elevation of the dock bottom foundation of the pouring area 40 and the outfitting area at the two sides; the outer dock entrance area 70 is located on the water facing side of the outfitting dock 60 and is provided with a submerged pipe 81 outlet, namely, measures such as outer dock blocks 71, outer dock gates 72, pump stations and the like are arranged, and water areas corresponding to foundation slots of the submerged pipe tunnel outside the outer dock gates 72 are used as a submerged pipe 81 delivery channel and a secondary outfitting area 80. Specifically, the position of the outer dock gate 72 is specifically set at the spatial position of the final joint of the foundation trench in water, and the top surface elevation of the outer dock gate bottom plate 73 (i.e. the dock bottom foundation of the outer dock gate area 70) and the height Cheng Jiping of the bottom foundation surface of the final joint are set, so that the operation of the dock gate and the final joint at the final joint space is satisfied, the installation of the final pipe joint is not influenced, the outer dock gate 72 can be closed in time after the final pipe joint is installed, the outfitting dock 60 can drain in time, and the construction of the onshore tunnel at the dry dock position is guaranteed as soon as possible; after the tunnel at the on-shore butt-joint end in the dock entrance is finished, water can be poured between the butt-joint end of the dock entrance and the outer dock gate, and the outer dock gate is opened and removed, so that the construction of the subsequent buried section at the on-shore butt-joint end is not influenced, the final joint at the position of the outer dock gate is not influenced, the outer sealing water is simultaneously made in water, and the operation process of the final joint is constructed in the tunnel; thus, two construction surfaces on the shore and in the water can be formed to work in parallel, thereby being beneficial to accelerating construction progress and shortening construction period.

Specifically, as shown in fig. 2, 4 and 8, in the steel bar binding area 30, a plurality of displacement rails 34 are arranged in parallel at positions corresponding to the binding bases, a plurality of load-carrying trolleys 351 are arranged on the displacement rails 34, the load-carrying trolleys 351 can roll along the displacement rails 34, and the load-carrying trolleys 351 on each displacement rail 34 are connected into a whole by arranging a bottom tire frame 35 at the top, so that the longitudinal displacement is facilitated; the bottom jig frame 35 comprises a plurality of rows of square steel and a pushing beam, the pushing beam is transversely fixedly connected to the ends of the plurality of rows of square steel, so that the plurality of rows of square steel are integrated, each loading trolley 351 can move synchronously during pushing, and the bottom jig frame 35 is used for supporting the reinforcement cage 33; the displacement track 34 is limited by adopting groove-shaped steel, a pushing device 36 is arranged at the land end of the binding pedestal, and the pushing device 36 pushes a pushing beam at the end part of the bottom jig frame 35, namely a synchronous pushing load trolley 351; the both sides of ligature pedestal are equipped with factory building track one 32, supply factory building gantry crane one 31 to remove to adapt to the adjustment operation of reinforcing bar ligature position, factory building track one 32 link up the setting at reinforcing bar ligature dock 20, and factory building track one 32 link up the both sides of pouring the pedestal from the both sides of reinforcing bar ligature pedestal, make things convenient for factory building gantry crane one 31 to remove to pouring the pedestal top like this. After the binding pedestal finishes binding the immersed tube reinforcement cage 33, the pushing device 36 is driven to push the bottom jig frame 35 to carry the immersed tube reinforcement cage 33 to shift, and the reinforcement cage 33 moves to the pouring area 40 along the shifting track 34 along with the loading trolley 351 under the bottom jig frame. The friction force of the steel reinforcement cage 33 is small, and compared with the mode of transferring the steel reinforcement cage 33 by the gantry crane, the operation is stable and simple, and the adverse conditions of bending deformation and the like of the steel reinforcement can be avoided.

In the pouring area 40, as shown in fig. 2, 9 and 10, two sides of the pouring pedestal along the line direction are respectively provided with a second factory building track 42 for the second factory building gantry 41 to move. Four first rail beams 43 and four second rail beams 44 are arranged on the ground at positions corresponding to the positions of the pouring pedestal, and foundation piles are arranged at intervals at the bottoms of the first rail beams 43 and the second rail beams 44; the first track beam 43 is arranged below the wall of the immersed tube 81, and the second track beam 44 is arranged corresponding to the position of the immersed tube through hole, so that uniform stress and force transmission are facilitated; the first rail beam 43 of the casting area 40 extends through the inner dock gate 52 to the outfitting area and serves as the basis of the outfitting pedestal. The first rail beam 43 is correspondingly provided with a trolley rail 431 and two rows of buttresses 90 along the line transportation direction, the two rows of buttresses 90 are positioned at two sides of the trolley rail 431, and the buttresses 90 are respectively arranged at positions corresponding to the stations where the pouring pedestal and the outfitting pedestal are positioned at intervals to form a main body of the corresponding pedestal; a row of buttresses 90 are also arranged on the second track beam 44 at the pouring station at intervals and are used for supporting the pouring load of the immersed tube bottom plate. The displacement trolley 64 is arranged on the trolley track 431, the displacement trolley 64 comprises a plurality of trolley bodies, a driving device used for driving the trolley bodies to walk and a jack arranged on the trolley bodies, the trolley bodies are arranged at intervals, two adjacent trolley bodies are connected through a connecting rod, and the displacement trolley 64 is used for transferring a pouring-molded immersed tube 81 to an outfitting pedestal of an outfitting area, namely, an abutment 90 of an outfitting station along the trolley track 431.

The bottom die 45 is arranged at the top of the buttress 90 at the pouring station, the movable bottom die 45 is arranged at the top of the shifting trolley 64, and before pouring operation, the bottom die 45 is leveled in height to support the pouring operation; when the reinforcement cage 33 is pushed onto the pouring pedestal, the loading trolley 351 is supported on the bottom die 45, then the reinforcement cage 33 is lifted by the first factory door hanger 31 and the second factory door hanger 42, then the bottom jig frame 35 at the bottom of the reinforcement cage 33 is moved out, and the reinforcement cage is returned to the binding area again, so that time and labor are saved; after the casting work of the immersed tube 81 in the casting area 40 is completed, the immersed tube 81 is lifted up by the movable displacement trolley 64 and transferred to the outfitting area along the through trolley rail 431.

Each buttress 90 in the outfitting area is provided with a passive support 63, and the passive device is used for realizing height adjustment, so that the immersed tube 81 can be horizontally placed on the passive support 63, and the passive support 63 is an existing device and is not described herein. The factory building track three 62 is arranged on the two sides of the outfitting pedestal of the outfitting area, and the factory building track three 62 is used for moving the factory building gantry crane three 61 of the area, so that one-time outfitting is convenient to perform. The third factory building track 62 and the first factory building track 32 can be arranged in the same line, so that line arrangement is simplified and reasonable arrangement is achieved.

In operation, the process flow of the pipeline prefabricated immersed tube 81 is as follows:

(1) Processing the rebar in an off-dock rebar processing plant 10;

(2) The processed steel bars are transported to a binding factory building of a binding dock along a lower dock channel 22 by a transport vehicle, and the steel bars are integrally bound with bottom plate steel bars and wall steel bars on a binding pedestal by a crane and a man power in the factory building;

(3) Then pushing the integral internal mold 46 into the reinforcement cage 33, and integrally binding a top plate reinforcement on the throughout-length internal mold 46;

(4) After the reinforcement cage 33 is bound, pushing the reinforcement cage bottom jig frame 35 through the pushing device 36, and carrying the bound whole reinforcement cage 33 and the internal mold 46 by the bottom jig frame 35 to shift from a binding station to a pouring station;

(5) The reinforcement cage 33 lifts the reinforcement cage 33 by the crane above the binding plant and the pouring plant, so that the bottom jig frame 35 below the reinforcement cage 33 is moved out and returned to the binding area;

(6) Placing the reinforcement cage 33 on a pouring pedestal, installing an outer die 47 and an end die, and pouring concrete segment by segment in sequence;

(7) After pouring, after the concrete strength is enough, dismantling the inner mould 46, moving the inner mould 46 plate from the pouring pedestal to the reinforcement cage 33 of the next pipe joint of the binding pedestal, continuing to bind the top plate reinforcement of the next pipe joint, and repeatedly applying the dismantled inner mould 46 to the step (3);

(8) The poured pipe joint lifts the immersed tube 81 through the shifting trolley 64 below the pouring pedestal and the jack on the shifting trolley 64, the immersed tube 81 is shifted to the outfitting pedestal position of the outfitting dock 60, the immersed tube 81 is converted on the outfitting pedestal, and the shifting trolley 64 is retracted to the pouring area for repeated use;

(9) The pipe joints are outfitted once through the gantry crane and the outfitting equipment of the outfitting area;

(10) After the outfitting is finished once, the gantry crane, the outfitting equipment and the like are returned to the reinforcement bar binding dock 20 (i.e. the internal dock);

(11) Closing the inner dock gate 52 by a mobile crane or a gate opening device, and installing an inner dock gate 52 water stop device;

(12) Filling water into the outfitting dock 60 through the water filling and draining equipment of the outer dock entrance to float the pipe joint;

(13) An open outer dock gate 72, which is used for stranding the pipe joint to a secondary outfitting area outside the dock through a cable stranding system, and then carrying out subsequent secondary outfitting and sinking installation procedures on the pipe joint;

(14) Closing the outer dock gate 72, draining water in the outfitting dock 60 through water filling and draining equipment of the outer dock gate, and cleaning the outfitting dock 60;

(15) The water stop device of the inner dock gate 52 is removed, the inner dock gate 52 is opened through a crane or a gate opening mechanism, the poured next pipe joint is moved to the outfitting dock 60 through the shifting trolley 64 on the pouring pedestal in the steel bar binding dock 20, the next pipe joint is circularly outfitted, the pipe joint is prefabricated in the assembly line, and the period of one prefabricated pipe joint is about 1 month.

The economic advantage of the axial dry dock is fully utilized, the foundation trench of the tunnel land buried section and the open section is utilized as a dry dock factory, the dry dock factory and the matched operation process of the prefabricated immersed tube 81 can be provided by combining the process characteristics of the immersed tube 81 factory method, the dry dock or the factory building, the harbor pool building, the large semi-submerged ship matching and the like do not need to be additionally found, the problem that the large temporary construction facilities need to be built for the factory method prefabricated immersed tube 81 is solved, the advantages of short construction period, good quality, controllable risk and the like of the factory method assembly line prefabricated immersed tube 81 are reserved, and the prefabrication period is 1-2 months.

Finally, the term "dock" as used herein, such as "rebar tying dock 20", "outfitting dock 60", etc., refers to a place (generally referred to as a "high-surrounding" place) with a concave center, and is used for various purposes.

Example 2

The embodiment further provides a dry dock system for prefabricating a immersed tube tunnel in a production line and a prefabricating method thereof, and the main difference of the embodiment compared with the embodiment 1 is that: the dry dock system in this embodiment adopts a single dock mode, as shown in fig. 15-17, that is, the site excavation of the reinforcement bar binding dock 20 in embodiment 1 is canceled, the reinforcement bar binding area 30 for prefabricating the reinforcement bar cage 33 is set outside the dock, the casting pedestal is set in the outfitting dock 60, the casting and outfitting processes share the same pedestal, and accordingly, the gantry crane is arranged above the casting pedestal and the devices such as the concrete casting machine 48, the pump pipe 481 and the like are arranged; specifically, in this embodiment, the reinforcement bar binding area 30 is adjacent to the land end of the outfitting dock 60, and gantry rails are disposed on two sides of the outfitting dock 60 along the line direction, and penetrate to the reinforcement bar binding area 30 for gantry movement. The construction method comprises the following steps:

s1, prefabricating a immersed tube reinforcement cage 33 in a reinforcement binding area 30 outside a dock;

s2, after binding is completed, the reinforcement cage 33 is moved to a pouring pedestal section by using a gantry crane in the reinforcement binding area 30, and pouring operation is carried out;

s3, after the immersed tube pouring is completed, continuously performing one-time outfitting operation on the pouring pedestal;

s4, after one-time outfitting is finished, the outfitting dock 60 is irrigated through irrigation and drainage equipment of an outer dock entrance, so that the immersed tube 81 floats;

s5, opening an outer dock gate 72, and twisting the immersed tube 81 out of the dock;

s6, secondary outfitting is carried out after the immersed tube 81 is undocked, meanwhile, the outer dock gate 72 is closed, water is drained into the outfitting dock 60 through water filling and draining equipment of the outer dock gate, and the outfitting dock 60 is cleaned; and (3) moving the steel reinforcement cage of the next pipe joint bound in the binding area 30 to the outfitting dock 60 through a gantry crane, and sequentially and circularly pouring and outfitting the next pipe joint.

According to the embodiment, the dry dock system adopts a single dock mode, so that the engineering quantity of excavation and cofferdam is small, the occupied area is small, and correspondingly, the later backfilling engineering quantity is reduced. In the operation process, the prefabricated reinforcement cage 33, pouring and outfitting procedures of the immersed tube 81 prefabricating process are divided into two stations for partition synchronous construction, wherein the pouring procedure and the outfitting procedure are carried out at the same station, the outfitting procedure is carried out by floating the outfitting dock 60 after one-time outfitting, the prefabricating period is about 2 months, the limitations of ship searching and wharf are avoided, the prefabricating site scale is reduced, the method is suitable for construction in limited and short areas, and the construction difficulty and investment cost are reduced.

Example 3

The embodiment also provides a dry dock system for prefabricating a immersed tube tunnel in a production line and a prefabricating method thereof, as shown in fig. 18-20, compared with the embodiment 1, the main difference of the technical scheme of the embodiment is that: in this embodiment, the reinforcement bar binding dock 20 of the dry dock system is only used for reinforcement bar binding operation, the outfitting dock 60 is used for pouring and outfitting operation, the pouring pedestal is arranged on the outfitting dock 60, the pouring and outfitting processes share the same station pedestal, and accordingly, a plurality of door hangers are distributed in the outfitting dock and are used for hoisting and pouring respectively. The construction process includes the following steps:

s1, prefabricating a immersed tube reinforcement cage 33 in a reinforcement binding area 30;

s2, firstly, carrying the reinforcement cage 33 by using a pushing device 36 through a loading trolley 351, pushing the reinforcement cage onto a pouring pedestal along a displacement track 34, and performing pouring operation; when the reinforcement cage is shifted to the inner dock area, the reinforcement cage 33 can be lengthened and extended to the pouring pedestal in a mode of overlapping the shifting rail 34 in the inner dock area and the outfitting dock, so that the shifting of the reinforcement cage 33 is stably transited;

s3, after the immersed tube pouring is completed, continuously performing one-time outfitting operation on the pouring pedestal;

s4, after one outfitting is completed, returning the gantry crane and the outfitting equipment to the steel bar binding dock 20, and then closing the inner dock gate 52;

s5, filling water into the outfitting dock 60 to enable the immersed tube 81 to float;

s6, opening an outer dock gate 72, stranding a immersed tube 81 out of the dock, and performing secondary outfitting;

s7, after undocking, closing an outer dock gate 72, and draining and cleaning the outfitting dock 60;

s8, opening an inner dock gate 52, transferring the next reinforcement cage 33 from the reinforcement binding area 30 to a pouring pedestal, and performing pouring and outfitting operations on the pouring pedestal in a circulating manner.

The prefabricated reinforcement cage 33, pouring and outfitting procedures of the immersed tube 81 prefabricating process are divided into two stations for partition synchronous construction by adopting a double-dock mode, wherein the pouring procedure and the outfitting procedure are carried out at the same station, the outfitting procedure is carried out after one-time outfitting is completed by filling water into the outfitting dock 60 to float out, the prefabricating period is about 2 months, the limitations of ship searching and wharf are avoided, the prefabricating site scale is reduced, the method is suitable for construction in areas with limited length and smaller area, and the construction difficulty and investment cost are reduced. The process of prefabricating the reinforcement cage 33 can be carried out in a dry dock or outside the dock, and the process is selected according to the construction conditions of a specific site.

In the method, two or more binding pedestals, pouring pedestals or outfitting pedestals, such as two-production-line four-pedestal double-dock factories or two-production-line six-pedestal double-dock factories, can be arranged in a factory system according to construction requirements and site selection working conditions, wherein a batch of pipe joints are prefabricated for 2 months in the two-production-line four-pedestal double-dock factories, and each batch of pipe joints is 2 pipe joints; two production lines six-seat double-dock factory prefabricated a batch of pipe joints for 1 month, 2 pipe joints per batch, not limited to the above examples. Moreover, the technical solutions in embodiments 1-3 can also be used for independently locating and constructing dry dock factories according to the site situation and the requirement, and are not limited to the axial dry dock construction.

The prefabrication method provided in the above embodiments 1-3 prefabricates the immersed tube tunnel by adopting the method of regional synchronous construction, and the immersed tube fitting is undocked by floating after one-time outfitting, so that the prefabrication period is short, the required field scale is small, the prefabrication method is not limited by semi-submerged barge and wharf, the prefabrication field scale can be adjusted according to actual construction conditions, the occupied area is flexible, a single dock and a double dock can be arranged, the environmental adaptability is good, and the addressing difficulty of the temporary construction field is reduced.

The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the invention.

Claims (10)

1. The prefabrication method of the prefabricated immersed tube tunnel based on the dry dock system assembly line is characterized in that the dry dock system comprises a steel bar binding dock (20) and an outfitting dock (60) which are communicated, wherein a steel bar binding area (30) and a pouring area (40) are arranged in the steel bar binding dock (20), an inner dock gate (52) is arranged between the steel bar binding dock (20) and the outfitting dock (60) and used for being switched on and off, an outer dock gate (72) is arranged on the water facing side of the outfitting dock (60) and used for being switched on and off, and the prefabrication method comprises the following steps during construction:

step one, prefabricating a reinforcement cage (33) of a immersed tube (81) in the reinforcement binding area (30);

step two, the reinforcement cage (33) is moved to the pouring area (40) for pouring operation;

step three, transferring the immersed tube (81) after pouring to the outfitting dock (60) for one outfitting operation;

closing an inner dock gate (52), and filling water into the outfitting dock (60) to float a sinking pipe (81);

and fifthly, opening the outer dock gate (72) and stranding the immersed tube (81) out of the dock.

2. Prefabrication method according to claim 1, characterized in that the reinforcement cage (33) is pushed from the reinforcement binding area (30) to the pouring area (40) along a displacement track (34) with a pushing device (36), wherein a base jig frame (35) is provided below the reinforcement cage (33), a load trolley (351) is fixedly mounted below the base jig frame (35), the load trolley (351) being capable of rolling along the displacement track (34); and at a station to be poured in the pouring area (40), lifting the reinforcement cage (33) through a gantry crane, pulling out the bottom jig frame (35), and returning to the reinforcement binding area (30).

3. Prefabrication method according to claim 1, characterized in that the caisson (81) is transferred from the pouring area (40) to the outfitting dock (60) by means of a displacement trolley (64) with lifting function, the caisson (81) is transferred to support on an outfitting bench in the outfitting dock (60), and the displacement trolley (64) is then withdrawn back to the pouring area (40).

4. A prefabrication method according to claim 1, characterized in that after the one outfitting operation has been completed, both the gantry crane and the outfitting equipment are moved out of the outfitting dock (60), retracted into the reinforcement bar lashing dock (20) and the internal dock gate (52) is closed.

5. The prefabrication method according to any of the claims 1-4, wherein it further comprises the step six: closing the outer dock gate (72) after the caisson (81) is undocked, and draining the outfitting dock (60); and then opening the inner dock gate (52) and transferring the next poured immersed tube joint to the outfitting dock (60).

6. Dry dock system for implementing a prefabrication method according to any of the claims 1-5, characterized in that it comprises a reinforcement bar binding dock (20), an outfitting dock (60) and a secondary outfitting area (80), wherein a reinforcement bar binding area (30) and a pouring area (40) are arranged in the reinforcement bar binding dock (20), the reinforcement bar binding dock (20) is communicated with the outfitting dock (60), an inner dock gate (52) is arranged between the reinforcement bar binding dock (20) and the outfitting dock (60) for on-off, an outer dock gate (72) is arranged on the water facing side of the outfitting dock (60) for on-off, the outfitting dock (60) is located in a land buried section of a tunnel, and the secondary outfitting area (80) is located in an open section of a foundation trench in water adjacent to the land buried section.

7. The prefabrication method for prefabricating the immersed tube tunnel based on the dry dock system assembly line is characterized in that the dry dock system comprises an outfitting dock (60), a pouring pedestal is arranged in the outfitting dock (60), an outer dock gate (72) is arranged on the water facing side of the outfitting dock (60) for on-off, and the method comprises the following steps of:

moving the prefabricated reinforcement cage (33) to the pouring pedestal for pouring operation;

after pouring is completed, continuing to perform one-time outfitting operation on the immersed tube (81) on the pouring pedestal;

after the outfitting operation is completed, water is poured into the outfitting dock (60) to float the immersed tube (81);

and opening the outer dock gate (72) again, and stranding the immersed tube (81) out of the dock.

8. The prefabrication method according to claim 7, wherein the reinforcement bar binding area (30) of the prefabricated reinforcement bar cage (33) is arranged outside the dock, and the reinforcement bar cage (33) is transferred to the pouring pedestal by means of a gantry crane.

9. The prefabrication method according to claim 7, wherein the dry dock system further comprises a rebar tying dock (20), the rebar tying dock (20) is used as a rebar tying zone (30), the rebar tying dock (20) is communicated with the outfitting dock (60), and an inner dock gate (52) is arranged between the rebar tying dock (20) and the outfitting dock (60) for switching on and off; when the steel reinforcement cage (33) is shifted, the pushing device (36) is adopted to push the steel reinforcement cage (33) onto the pouring pedestal along the shifting track (34), a bottom jig frame (35) is arranged below the steel reinforcement cage (33), a loading trolley (351) is fixedly arranged below the bottom jig frame (35), and the loading trolley (351) can roll along the shifting track (34).

10. Dry dock system for carrying out the prefabrication method according to any of the claims 7-9, characterized in that it comprises a land-based buried section for tunnel construction and an open section of a foundation trench in water adjoining the land-based buried section, a dry dock is arranged on the land-based buried section, a secondary outfitting area (80) is arranged on the open section of the foundation trench in water, the dry dock is used for casting and primary outfitting operations and the casting and primary outfitting operations are located at the same station.

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