Box culvert construction process

Abstract

The invention relates to a box culvert construction process, which relates to the field of expressway box culvert construction, and comprises the following steps: after construction of a bottom plate and part of side walls of a box culvert is completed, dividing the whole box culvert into four construction sections by adopting a skip pouring mode, namely a pouring completion maintenance area, a slip form construction area, a steel bar pre-binding area and a construction preparation area; a formwork supporting frame device is assembled; the formwork device is moved to a slip form construction area and positioned; pouring construction is conducted on the slip form construction area; after pouring of one box culvert bin section is completed and the formwork removing condition is met, the side formworks are removed, then the top formwork is removed, and a pouring completed curing area is formed; the formwork device is moved to a constructed reinforcing steel bar pre-binding area, and repeated pouring construction is carried out; and box culvert construction operation is completed. The device has the effects that the template is automatically adjusted, the frame body is convenient to move, and positioning is simple.

Description

Technical Field

[0001] The present application relates to the field of highway box culvert construction, and in particular to a box culvert construction process. Background Art

[0002] Traditional highway box culvert construction techniques mostly involve assembling steel formwork or using steel formwork trolleys. Combining steel formwork requires repeated installation and removal of brackets and steel formwork, requiring a heavy workload involving manual labor and the coordination of truck cranes. Conventional formwork installation and removal is labor-intensive, with multiple steps and long lead times, requiring significant investment in both manpower and resources. This not only poses high safety risks and increases the risk of steel rust, but also exposes the formwork to deformation, damage, and contamination, making the concrete's appearance difficult to guarantee. Steel formwork trolley construction techniques are expensive, large, and heavy, making them difficult to modify and relocate. This makes them unsuitable for the scattered, numerous, angled, and diverse box culverts found on highways. Summary of the Invention

[0003] In order to solve the above technical problems, the present application provides a box culvert construction process.

[0004] The box culvert construction process provided in this application adopts the following technical solution:

[0005] A box culvert construction process comprises the following steps:

[0006] After the construction of the box culvert bottom plate and part of the side wall is completed, the whole box culvert is divided into four "construction sections" by using the skip-casting method: the curing area after casting, the slipform construction area, the steel bar pre-binding area, and the construction preparation area;

[0007] Assembling formwork support devices;

[0008] Move the formwork device to the slipform construction area and position it;

[0009] Carry out pouring construction in the slipform construction area;

[0010] After the pouring of a box culvert section is completed and the conditions for formwork removal are met, the side formwork is removed, and then the top formwork is removed to form a curing area after pouring;

[0011] Move the formwork device to the completed steel bar pre-binding area for repeated pouring construction;

[0012] Complete the box culvert construction work.

[0013] Furthermore, the formwork device includes a support system, a template system respectively arranged on the top and both sides of the support system, and a walking system arranged below the support system. An adjustment system is provided between the template system and the support system, a control system is provided at the bottom of the support system, and the walking system is used to drive the support system to move.

[0014] Furthermore, the support system includes four columns and several beams, and the several beams are evenly distributed between the four columns and welded together. A support seat is provided at the bottom of the column, and a universal wheel is provided at the bottom of the beam. The bottom of the universal wheel is in contact with the top of the walking system.

[0015] Furthermore, the formwork system includes a top formwork, an angle formwork, a steel top formwork and two side forms, wherein one of the side forms is arranged on one side of the support system, and the other side formwork is arranged on the other side of the support system, and the side formwork is composed of several pieces of formwork, and the side formwork is provided with longitudinal main ribs and transverse secondary ribs near the side wall of the support system, the top formwork is arranged at the top of the support system, and the top formwork is composed of several pieces of formwork, and the top formwork is provided with back ribs on the side wall facing the support system, the steel top formwork is arranged on both sides of the top formwork, the angle formwork is arranged between the top formwork and the side formwork and is arranged obliquely, and several formwork drainage outlets are arranged inside the formwork, and the side formwork and the top formwork are connected to the support system through steel back ribs and U-shaped clips.

[0016] Furthermore, the adjustment system includes an electric corner mold lifter, a manual top mold lifter, a manual side mold lifter, an electric frame lifter and a manual wall pusher. The electric corner mold lifter is arranged between the corner mold and the column, the manual top mold lifter is arranged between the top mold and the column, the manual side mold lifter is arranged on the column for adjusting the height of the support seat, and the manual wall pusher is arranged between the side mold and the column.

[0017] Furthermore, the control system includes a control box and a PLC controller. The PLC controller is located inside the control box and is electrically connected to the electric corner mold lifter and the electric frame lifter. The adjustment of the template system is completed through the control of the PLC controller.

[0018] Furthermore, the walking system includes a driving cover, a rotating chassis, track wheels, tracks and a driving battery for providing power. The rotating chassis is located under the driving cover and a driving motor is provided inside the driving cover for driving the rotating chassis to rotate in place. The track wheels are located under the rotating chassis and are connected to the tracks.

[0019] In summary, this application includes at least one of the following beneficial technical effects:

[0020] 1. The use of an adjustable combined bracket system as the supporting structure enables rapid assembly of the formwork system and universal use of box culverts of different sizes and types. The bottom is equipped with a walking system to enable rapid conversion of the equipment from the "overall ground support state" during concrete pouring construction to the "roller walking state" after formwork removal. The crawler wheels are used to drive the crawler to move, and then the walking system drives the entire bracket system to move to the slipform construction area. At this time, the electric frame lift is used to lower the support seat so that the support seat contacts the ground, realizing the positioning of the bracket system. The electric corner form lift is used to extend the corner form, the manual top form lift is used to extend the top form, and the manual side form lift is used to extend the side form to form a pouring space, and then pouring is carried out. After pouring is completed, the formwork is removed to form a curing area for pouring completion, which is conducive to achieving the effects of automatic formwork adjustment, convenient frame movement, and simple positioning;

[0021] 2. The template system is controlled by a PLC controller to achieve automatic and precise positioning of the template, avoiding a lot of time and manpower to install, disassemble and adjust the template position, effectively reducing labor intensity and improving work efficiency;

[0022] 3. The adjustment system is equipped with both electric and manual adjustment modes, which improves the fault tolerance rate and avoids the electric adjustment being unusable due to insufficient power supply on site. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the overall structure of a box culvert construction process in an embodiment of the present application.

[0024] Figure 2 This is a schematic diagram of the overall structure of the template system used in the embodiment of the present application.

[0025] Figure 3 This is a schematic diagram of the overall structure of the support system used in the embodiment of the present application.

[0026] Figure 4 This is a schematic diagram of the overall structure of the regulation system in the embodiment of the present application.

[0027] Figure 5 This is a schematic diagram of the overall structure of the control system in the embodiment of the present application.

[0028] Figure 6 This is a schematic diagram of the overall structure of the walking system in the embodiment of the present application.

[0029] Explanation of the accompanying reference numerals: 1. Formwork system; 2. Support system; 3. Adjustment system; 4. Control system; 5. Travel system; 6. Side formwork; 7. Top formwork; 8. Corner formwork; 9. Steel top formwork; 10. Formwork; 11. Longitudinal main rib; 12. Horizontal secondary rib; 13. Back rib; 14. Column; 15. Beam; 16. Support seat; 17. Universal wheel; 18. Electric corner formwork lift; 19. Manual top formwork lift; 20. Manual side formwork lift; 21. Electric frame lift; 22. Manual wall pushing machine; 28. Control box; 29. ​​PLC controller; 30. Drive cover; 31. Rotating chassis; 32. Track wheel; 33. Track; 34. Drive battery; 35. Formwork drain outlet. DETAILED DESCRIPTION

[0030] The following is combined with Figure 1-6 This application is described in further detail.

[0031] The embodiment of the present application discloses a box culvert construction process.

[0032] Reference Figure 1 , a box culvert construction process includes the following steps:

[0033] After the construction of the box culvert bottom plate and part of the side wall is completed, the whole box culvert is divided into four "construction sections" by using the skip-casting method: the curing area after casting, the slipform construction area, the steel bar pre-binding area, and the construction preparation area;

[0034] Assembling formwork support devices;

[0035] Move the formwork device to the slipform construction area and position it;

[0036] Carry out pouring construction in the slipform construction area;

[0037] After the casting of a box culvert section is completed and the conditions for demoulding are met, the side formwork 6 is removed, and then the top formwork 7 is removed to form a curing area after casting;

[0038] Move the formwork device to the completed steel bar pre-binding area for repeated pouring construction;

[0039] Complete the box culvert construction work.

[0040] Reference Figure 1 The formwork device includes a support system 2, a template system 1 respectively arranged on the top and both sides of the support system 2, and a walking system 5 arranged below the support system 2. An adjustment system 3 is arranged between the template system 1 and the support system 2, a control system 4 is arranged at the bottom of the support system 2, and the walking system 5 is used to drive the support system 2 to move.

[0041] Reference Figure 6The walking system 5 includes a driving cover 30, a rotating chassis 31, track wheels 32, tracks 33 and a driving battery 34 for providing power. The rotating chassis 31 is located below the driving cover 30 and a driving motor is provided inside the driving cover 30 for driving the rotating chassis 31 to rotate in place. The track wheels 32 are located below the rotating chassis 31 and are connected to the tracks 33.

[0042] Reference Figure 3 The support system 2 includes four columns 14 and several beams 15. The beams 15 are evenly distributed between the four columns 14 and welded together. A support seat 16 is provided at the bottom of the column 14, and a universal wheel 17 is provided at the bottom of the beam 15. The bottom of the universal wheel 17 is in contact with the top of the driving cover 30, so that the support system 2 can adjust its position slightly when the support seat 16 has not yet contacted the ground.

[0043] Reference Figure 2 The formwork system 1 includes a top formwork 7, an angle formwork 8, a steel top formwork 97 and two side forms 6, wherein one side formwork 6 is arranged on one side of the support system 2, and the other side formwork 6 is arranged on the other side of the support system 2. The side formwork 6 is composed of several pieces of formwork 10. The side formwork 6 is close to the side wall of the support system 2 and is provided with a longitudinal main rib 11 and a transverse secondary rib 12. The top formwork 7 is arranged on the top of the support system 2. The top formwork 7 is composed of several pieces of formwork 10. The top formwork 7 is provided with a back rib 13 on the side wall facing the support system 2. The steel top formwork 97 is arranged on both sides of the top formwork 7. The corner formwork 8 is arranged between the top formwork 7 and the side formwork 6 and is arranged at an angle. Several formwork drainage outlets 35 are arranged inside the formwork. In this embodiment, the formwork adopts a specification of 1350mm×600mm. The side formwork 6 and the top formwork 7 are connected to the support system 2 through steel back ribs 13 and U-shaped clips.

[0044] In this embodiment, the support system 2 together with the control system 4 and the adjustment system 3 are transported to the site by a transport vehicle after being welded by the manufacturer, and the template system 1 is assembled on site.

[0045] The assembly process is as follows: 1. Assemble the support system 2; 2. Splice the side formwork 6 and the PERI formwork 10; 3. Connect the side formwork 6 to the PERI formwork 10 using clips; 4. Hoist the side formwork 6 to the support system 2 and connect it to it; 5. Install the back rib 13 of the top formwork 7; 6. Install the corner formwork 8 and the steel top formwork 97; 7. Install the top formwork 7; 8. Install and debug the control system 4; 9. Install the walking system 5 in place.

[0046] Reference Figure 4The adjustment system 3 includes an electric corner mold lift 18, a manual top mold lift 19, a manual side mold lift 20, an electric frame lift 21 and a manual wall pusher 22. The electric corner mold lift 18 is arranged between the corner mold 8 and the column 14, the manual top mold lift 19 is arranged between the top mold 7 and the column 14, the manual side mold lift 20 is arranged on the column 14 for adjusting the height of the support seat 16, and the manual wall pusher 22 is arranged between the side mold 6 and the column 14.

[0047] The use of an adjustable combined bracket system 2 as a supporting structure enables the rapid assembly of the formwork system 1 and the universal use of box culverts of different sizes and types. The bottom is equipped with a walking system 5, which enables the equipment to quickly switch from the "overall ground support state" during concrete pouring construction to the "roller walking state" after demolding. The crawler wheel 32 is used to drive the crawler 33 to move, and then the walking system 5 drives the overall bracket system 2 to move to the slipform construction area. At this time, the electric frame lift 21 is used to lower the support seat 16 so that the support seat 16 contacts the ground, thereby realizing the positioning of the bracket system 2. The electric corner mold lift 18 is used to drive the corner mold 8 to extend, the manual top mold lift 19 drives the top mold 7 to extend, and the manual side mold lift 20 drives the side mold 6 to extend to form a pouring space, and then pouring is carried out. After pouring is completed, the mold is removed to form a pouring completion curing area, which is conducive to achieving the effects of automatic adjustment of the formwork 10, convenient frame movement, and simple positioning.

[0048] The adjustment system 3 is equipped with both electric and manual adjustment modes, which improves the fault tolerance rate and avoids the electric adjustment being unusable due to insufficient power supply on site.

[0049] Reference Figure 5 The control system 4 includes a control box 28 and a PLC controller 29. The PLC controller 29 is located inside the control box 28 and is electrically connected to the electric corner mold lift 18 and the electric frame lift 21. The adjustment of the template system 1 is completed through the control of the PLC controller 29.

[0050] The template system 1 is controlled by the PLC controller 29 to achieve automatic and precise positioning of the template, avoiding a lot of time and manpower to install, disassemble and adjust the template position, effectively reducing labor intensity and improving work efficiency.

[0051] The implementation principle of a box culvert construction process in an embodiment of the present application is as follows: an adjustable combined support system 2 is used as a support structure to realize the rapid assembly of the formwork system 1, and to realize the universality of box culverts of different sizes and types; the bottom is equipped with a walking system 5 to realize the rapid conversion of the equipment from the "overall ground support state" during concrete pouring construction to the "roller walking state" after demolding; the crawler wheel 32 is used to drive the crawler 33 to move, and then the walking system 5 drives the overall support system 2 to move to the slipform construction area; at this time, the electric frame lift 21 is used to lower the support seat 16 so that the support seat 16 contacts the ground, realizing the positioning of the support system 2; the electric corner mold lift 18 is used to drive the corner mold 8 to extend, the manual top mold lift 19 drives the top mold 7 to extend, and the manual side mold lift 20 drives the side mold 6 to extend, forming a pouring space, and then pouring is carried out. After the pouring is completed, the mold is removed to form a pouring completion curing area, which is conducive to achieving the effects of automatic adjustment of the template, convenient frame movement, and simple positioning. The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A box culvert construction process, characterized by: The following steps are involved: After the construction of the box culvert bottom plate and part of the side wall is completed, the entire box culvert is divided into four "construction sections" using the skip-casting method: the curing area after casting, the slipform construction area, the steel bar pre-binding area, and the construction preparation area; Assembling formwork support devices; Move the formwork device to the slipform construction area and position it; Carry out pouring construction in the slipform construction area; After the pouring of a box culvert section is completed and the conditions for formwork removal are met, the side formwork is removed, and then the top formwork is removed to form a curing area after pouring; Move the formwork device to the completed steel bar pre-binding area for repeated pouring construction; Complete the box culvert construction work.

2. A box culvert construction process according to claim 1, characterized in that: The formwork device comprises a support system (2), a template system (1) respectively arranged on the top and two sides of the support system (2), and a walking system (5) arranged below the support system (2); an adjustment system (3) is arranged between the template system (1) and the support system (2); a control system (4) is arranged at the bottom of the support system (2); and the walking system (5) is used to drive the support system (2) to move.

3. A box culvert construction process according to claim 2, characterized in that: The support system (2) includes four columns (14) and a plurality of cross beams (15), wherein the cross beams (15) are evenly distributed between the four columns (14) and are welded together, a support seat (16) is provided at the bottom of the column (14), and a universal wheel (17) is provided at the bottom of the cross beam (15), and the bottom of the universal wheel (17) is in contact with the top of the walking system (5).

4. A box culvert construction process according to claim 2, characterized in that: The template system (1) comprises a top template (7), an angle template (8), a steel top template (9) and two side templates (6), wherein one of the side templates (6) is arranged on one side of the support system (2), and the other side template (6) is arranged on the other side of the support system (2). The side templates (6) are composed of a plurality of templates (10) spliced ​​together. The side templates (6) are provided with longitudinal main ribs (11) and transverse secondary ribs (12) near the side walls of the support system (2). The top template (7) is provided on the side walls of the support system (2). At the top, the top formwork (7) is composed of several templates (10) spliced ​​together, a back rib (13) is provided on the side wall of the top formwork (7) facing the support system (2), the steel top formwork (9) is provided on both sides of the top formwork (7), the angle formwork (8) is provided between the top formwork (7) and the side formwork (6) and is inclined, a plurality of template drainage ports (35) are provided inside the template, and the side formwork (6) and the top formwork (7) are connected to the support system (2) through the steel back rib (13) and the U-shaped buckle.

5. A box culvert construction process according to claim 3, characterized in that: The adjustment system (3) comprises an electric corner mold lift (18), a manual top mold lift (19), a manual side mold lift (20), an electric frame lift (21) and a manual wall pusher (22); the electric corner mold lift (18) is arranged between the corner mold (8) and the column (14); the manual top mold lift (19) is arranged between the top mold (7) and the column (14); the manual side mold lift (20) is arranged on the column (14) for adjusting the height of the support seat (16); and the manual wall pusher (22) is arranged between the side mold (6) and the column (14).

6. A box culvert construction process according to claim 2, characterized in that: The control system (4) includes a control box (28) and a PLC controller (29). The PLC controller (29) is located inside the control box (28) and is electrically connected to the electric corner mold lift (18) and the electric frame lift (21). The template system (1) is adjusted through the control of the PLC controller (29).

7. A box culvert construction process according to claim 2, characterized in that: The walking system (5) comprises a driving cover plate (30), a rotating chassis (31), track wheels (32), a track (33) and a driving battery (34) for providing power, wherein the rotating chassis (31) is located below the driving cover plate (30) and a driving motor for driving the rotating chassis (31) to rotate in situ is provided inside the driving cover plate (30), and the track wheels (32) are located below the rotating chassis (31) and connected to the track (33).

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