Fabricated construction method and system for upper structure of jetty wharf

Abstract

The invention relates to the technical field of port engineering, and discloses an assembly type construction method and system for an upper structure of a jetty wharf, and the construction method comprises the following steps: after sinking a steel pipe pile, fixing and processing a pile head by using a hoop type pile cutting platform through static friction force between a hoop and the steel pipe pile; fully-prefabricated longitudinal and transverse beams are produced, the higher part is also used as a cast-in-place formwork, and shear-resistant steel bars and a cantilever structure are pre-buried; friction hoops with water stop pads are arranged on the steel pipe piles, and I-shaped steel is erected through connecting seats to form a construction platform; the prefabricated parts are hoisted and post-cast through the joints to form an integral structure, and finally a surface layer is cast and ancillary facilities are installed. By integrating related platforms, component systems and hoisting equipment, core construction is converted into land prefabrication and land-like operation, the problems that traditional construction is affected by sea conditions, the efficiency is low, quality is difficult to control, the safety risk is high, cost is high, and environmental disturbance is large are solved, and multiple targets are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of port engineering, in particular to an assembled construction method and system for the superstructure of a spur-dike wharf. BACKGROUND

[0002] In the construction of port engineering, the superstructure of a spur-dike wharf, which usually includes pile caps, longitudinal and transverse beams, faceplates, and auxiliary facilities, is the key to ensuring the functions of berthing and loading and unloading. At present, although some precast technologies have emerged in the field of superstructure construction of spur-dike wharfs, most of the related technologies are limited to the precast production of single components such as faceplates or pile caps. For the core load-bearing components such as longitudinal and transverse beams, the construction methods of cast-in-place or semi-precast are still widely used, and the many drawbacks of traditional construction processes have not been fundamentally solved.

[0003] Specifically, in the traditional construction method, a large number of operations need to be carried out directly at sea, which is significantly affected by adverse sea conditions such as wind and waves, and the effective operation time is limited, resulting in slow construction progress and low efficiency. The installation, pouring, and maintenance conditions of the formwork for cast-in-place concrete at sea are much worse than those on land, and quality defects such as cracks and segregation are prone to occur, making it difficult to ensure the stability and reliability of the engineering quality. Workers need to carry out operations such as formwork erection and reinforcement binding in the complex environment of high altitude and water, which has a high safety risk and is prone to cause safety accidents. At the same time, the construction of sea involves many ship equipment, and the construction period is long, which not only leads to high costs of large floating crane ships, barges, and other equipment and labor, but also causes continuous disturbance to the marine ecological environment and has a large environmental impact. Therefore, there is an urgent need for a new construction technology for the superstructure of a spur-dike wharf that can achieve efficient construction, ensure engineering quality, reduce safety risks, save engineering costs, and reduce environmental impact to meet the actual needs of port engineering construction. SUMMARY

[0004] The purpose of the present application is to provide an assembled construction method and system for the superstructure of a spur-dike wharf, which integrates a hoop-type pile-cutting platform, a fully precast component system, a frictional hoop platform system, and hoisting equipment to convert the core links of the construction of the superstructure of a spur-dike wharf into land precast and land-like operations, solving the problems of low efficiency of sea operations affected by sea conditions, uncontrollable quality of cast-in-place concrete, high safety risk of high-altitude and water operations, high costs caused by the investment of ship equipment, and large disturbance to the marine environment in traditional construction, and achieving the goals of efficient construction, reliable quality, controllable safety, cost savings, and low environmental impact.

[0005] The present application is implemented by the following technical solutions: An assembled construction method for the superstructure of a spur-dike wharf, comprising the following construction steps: S1. After the steel pipe pile is completed, the pile head is cut to the design elevation by the hoop type pile cutting platform, and the pile top anticorrosive coating is repaired; the hoop type pile cutting platform comprises a frame body and a hoop located at the middle part of the frame body, and the frame body is fixed to the outer side wall of the steel pipe pile through the static friction force between the hoop and the steel pipe pile; S2. The full-precast longitudinal and transverse beams and the full-precast cantilever structure are designed and produced according to the drawings, the cross-sectional height of the full-precast longitudinal and transverse beams is greater than the final design height, the excess part serves as a permanent lateral formwork for the subsequent cast-in-situ concrete, and shear-resistant steel bars are pre-buried; S3. The friction hoop is connected to the cut steel pipe pile, a water stop pad is arranged on the inner side of the friction hoop, and a construction platform I-beam is arranged on the connecting seat on the outer side of the friction hoop to form a friction hoop construction platform; S4. The precast longitudinal and transverse beams and the full-precast cantilever structure produced in step S2 are hoisted to the construction platform by hoisting equipment; S5. After the precast components are hoisted in place, the component-to-component steel bars are bound or welded, the joint formwork is installed, and then the concrete is poured in the joint area to form an integral structure; S6. The surface layer concrete is poured on the assembled upper structure, and the auxiliary facilities are installed.

[0006] In the scheme, the hoop type pile cutting platform is stably fixed to the steel pipe pile by using the static friction force, and the pile head cutting and anticorrosive repair are realized by the land-like operation of the drainage and sealing structure, thereby avoiding the instability of the traditional underwater operation. The full-precast longitudinal and transverse beams are designed in the form of “structure-formwork integration”, and the excess part serves as a cast-in-situ formwork, thereby greatly reducing the offshore formwork erection process. The precast components can ensure the concrete vibration, curing quality, and improve the structural size precision and durability in the land standardized production. Meanwhile, the friction hoop construction platform builds a stable and safe offshore operation surface through the structure system of the water stop pad, the connecting seat and the construction platform I-beam, thereby reducing the risk of high-altitude water-side operation. The precast components are precisely installed by the matched hoisting equipment, and then the integral structure is formed by the joint post-pouring, thereby significantly shortening the offshore operation cycle, reducing the ship equipment investment and marine environment disturbance, and finally realizing the multiple benefits of construction efficiency improvement, engineering quality guarantee, safety risk reduction, cost saving and environmental impact reduction.

[0007] As a further construction method, in the step S1, the hoop type pile cutting platform further comprises a drainage pump pit, a water pump and a drainage pipe, the water pump is arranged in the drainage pump pit, and the water pump is in communication with the drainage pipe, thereby draining the accumulated water in the frame body, providing a dry and stable operation environment for the pile head cutting and anticorrosive repair, and avoiding the problems of insufficient cutting precision and poor coating adhesion caused by seawater interference; The frame body includes a frame beam and a water baffle structure arranged on the frame beam, the water baffle structure is in sealing cooperation with the water stop pad, effectively blocks the infiltration of external seawater, further guarantees the dry and clean operation surface, improves the construction quality and efficiency of pile head treatment, and creates safe land-like operation conditions for the operator.

[0008] As a further construction method, in the step S1, the hoop type pile cutting platform further includes a latch beam, a latch beam sleeve and an oil hydraulic telescopic rod, the oil hydraulic telescopic rod drives the latch beam to extend and retract in the latch beam sleeve, so that the structures on both sides of the platform are rigidly connected, and the overall stability and carrying capacity of the platform are effectively improved, thereby avoiding the influence of platform shaking on the cutting accuracy of the pile head and the quality of the corrosion repair during the construction process.

[0009] As a further construction method, in the step S1, the pile head cutting adopts a hydraulic diamond wire saw or a high-pressure water jet cutting, and when the corrosion coating is repaired, a power tool is used to polish the damaged area, and then an underwater curing type epoxy resin paint is applied, which can further improve the quality stability and operation efficiency of the pile foundation treatment, and reduce the subsequent hidden dangers caused by the problems such as inaccurate cutting and insufficient coating adhesion in the traditional process.

[0010] As a further construction method, in the step S2, the full-precast longitudinal and transverse beams and the full-precast cantilever structure are made of C50-C60 marine concrete components and are formed by pouring into steel molds, and the size error of the mold is controlled within ±5mm; the steel bars are made of epoxy coated steel bars, and the components are demolded after being cured at constant temperature and humidity to 100% of the design strength, which can avoid defects such as cracks and insufficient strength caused by improper curing, and the finish and flatness of the full-precast longitudinal and transverse beams are detected after demolding, which improves the quality stability and assembly adaptability of the precast components.

[0011] As a further construction method, in the step S3, the friction hoop includes two semicircular steel hoops which are fastened by high-strength bolts, wherein the high-strength bolts are applied with a design torque in 2-3 times in the order of "first middle, then both ends, and diagonal synchronization", so that the static friction force between the friction hoop and the steel pipe pile is not less than 2.5 times of the maximum vertical load of the friction hoop construction platform, which can ensure that the friction hoop closely and uniformly fits the steel pipe pile; the construction platform I-beam includes longitudinal beams and transverse beams, the transverse beams are laid in a direction perpendicular to the longitudinal beams with a spacing of 0.8-1.2m, forming a regular and stable grid beam system, which not only guarantees the carrying capacity of the platform, but also provides a flat and safe operation surface for subsequent precast component hoisting and node construction.

[0012] As a further construction method, in order to improve hoisting efficiency and quality and reduce rework caused by positioning deviation, in step S4, the hoisting equipment is a special offshore bridge erecting machine or a large floating crane. When a dedicated offshore bridge erecting machine is used, its front outrigger is equipped with an adjustable transition section, the inner diameter of which is 100mm larger than the diameter of the steel pipe pile. The middle outrigger is equipped with a lateral movement mechanism, and the bridge erecting machine integrates an RTK-GPS positioning system with a positioning accuracy of ≤5mm. When using large floating crane vessels, during periods of low tide, wind speed < 6, and wave height < 1m, RTK-GPS beacons should be installed on prefabricated components for positioning assistance.

[0013] A prefabricated construction system for the superstructure of a breakwater wharf that implements the above construction method includes a fully prefabricated component system and a friction clamp platform system. The prefabricated component system includes prefabricated longitudinal and transverse beams and prefabricated cantilever structures. The cross-sectional height of the prefabricated longitudinal and transverse beams is greater than the final design height. The extended portion also serves as cast-in-place formwork and is pre-embedded with shear reinforcement. The pre-embedded shear reinforcement ensures that the prefabricated components and cast-in-place joints form a rigid whole, thereby improving the structural stress reliability. The friction clamp platform system includes a friction clamp, a connecting seat, a construction platform I-beam, and a friction clamp construction platform. The friction clamp has a water-stop pad on its inner side and is connected to the connecting seat on its outer side. The construction platform I-beam is erected on the connecting seat to form the friction clamp construction platform, which provides a stable and safe land-like working surface for offshore operations, effectively avoids the interference of wind and waves on construction, and reduces the risk of high-altitude water-adjacent operations.

[0014] It also includes a clamp-type pile cutting platform, which includes a frame body, clamps, drainage pump pit, water pump, drainage pipe, pin beam, pin beam sleeve and hydraulic telescopic rod. The frame body is fixed to the steel pipe pile by the clamp, the pin beam is inserted into the pin beam sleeve, and the hydraulic telescopic rod drives the pin beam to extend and retract, so that the frame body can be merged or separated, simplifying the platform installation and disassembly process and greatly improving the efficiency of offshore operations. The clamp-type pile cutting platform also includes an oil pump and an oil delivery pipe, wherein the oil pump provides power to the hydraulic telescopic rod through the oil delivery pipe.

[0015] To further reduce construction safety risks, the friction clamp platform system also includes pile clamping timber and transverse pile clamping channel steel. The pile clamping timber is placed between the friction clamp and the steel pipe pile, and the transverse pile clamping channel steel is placed on the outside of the friction clamp.

[0016] Compared with the prior art, the present invention has the following advantages and beneficial effects: This invention transfers complex processes such as offshore casting and formwork erection to standardized operations on land. With the combined application of clamp-type pile cutting platforms, friction clamp construction platforms, and hoisting equipment, it significantly reduces offshore operation time, eliminates the constraints of wind, waves, and tides on construction, effectively improves work efficiency, and greatly shortens the overall construction cycle. This invention constructs a stable, land-like working environment by using a sealed drainage design for the clamp-type pile cutting platform and a multi-reinforcement structure for the friction clamp construction platform, thereby reducing the duration of high-altitude and water-adjacent operations. Components such as the clamping timber and transverse clamping channel steel further enhance the platform's stability, comprehensively avoiding the safety hazards of traditional offshore construction from equipment to process, and ensuring the safety of operators. The fully precast components of this invention use C50-C60 marine concrete and epoxy-coated steel bars. They are cast using steel molds and cured under constant temperature and humidity, with dimensional errors controlled within ±5mm. Special testing of the mold surface ensures compatibility with cast-in-place construction. Furthermore, precise processes such as hydraulic diamond wire sawing are used for pile head cutting, and anti-corrosion repair is achieved through grinding and underwater curing coatings to achieve dense protection. High-strength micro-expansion concrete is poured into the joints to form a rigid whole. Quality is guaranteed throughout the entire process from component production to construction connection, avoiding defects such as cracks and segregation in traditional offshore cast-in-place construction, and improving the structure's corrosion resistance and service life. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and form part of this application, do not constitute a limitation thereof. In the drawings: Figure 1 A schematic diagram of the vertical cross-section of the underwater pile cutting construction platform device; Figure 2 This is a plan view of the underwater pile cutting construction platform device in the combined clamping state. Figure 3 A schematic diagram of the vertical cross-section of the underwater pile cutting construction platform device in the combined clamping state; Figure 4 This is a plan view of the underwater pile cutting construction platform device in the hoisted and separated state. Figure 5 A schematic diagram of the vertical cross-section of the underwater pile cutting construction platform device in the hoisted and separated state; Figure 6 A schematic diagram of the construction steps for the rapid cutting of underwater steel pipe pile heads; Figure 7 This is a schematic diagram showing the integration of fully prefabricated longitudinal and transverse beam components with cast-in-place structures. Figure 8 This is a schematic diagram of the vertical cross-section of a fully prefabricated longitudinal and transverse beam component; Figure 9 This is a schematic diagram of the friction clamp structure; Figure 10A schematic diagram of the combined structure of the friction clamp and the I-beam of the construction platform; Figure 11 A schematic diagram of the layer-by-layer installation structure of the friction clamp and the I-beam of the construction platform; Figure 12 This is a schematic diagram of the installation structure of the friction clamp construction platform; Figure 13 A schematic diagram of the working status of an offshore bridge erecting machine; Figure 14 This is a schematic diagram of the entire breakwater pier.

[0018] The attached diagram shows the markings and corresponding component names: 1-Steel pipe pile, 2-Water retaining plate structure, 3-Waterstop pad, 4-Clamping hoop, 5-Drainage pump pit, 6-Water pump, 7-Drainage pipe, 8-Pin beam, 9-Pin beam sleeve, 10-Hydraulic telescopic rod, 11-Oil delivery pipe, 12-Ladder, 13-Lifting point, 14-Frame beam, 15-Merging and intersecting edge, 16-Oil pump, 17-Friction clamping hoop, 18-Connecting seat, 19-Construction platform I-beam, 20-Construction platform, 21-Pile clamping timber, 22-Transverse pile clamping channel steel. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of the present invention are only used to explain the present invention and are not intended to limit the present invention. Example 1

[0020] This embodiment 1 provides a prefabricated construction method for the superstructure of a breakwater wharf, such as... Figures 1-14 As shown, the construction steps are as follows: S1. After the steel pipe pile driving is completed, the pile head is cut to the design elevation using a clamp-type pile cutting platform, and the anti-corrosion coating on the pile top is repaired; the clamp-type pile cutting platform includes a frame body and a clamp located in the middle of the frame body, and the frame body is fixed to the outer wall of the steel pipe pile by the static friction between the clamp and the steel pipe pile. This step aims to complete the cutting and corrosion repair of the pile head of steel pipe pile 1, providing a flat and reliable supporting foundation for the construction of the superstructure. It utilizes a clamp-type pile cutting platform to achieve land-based underwater operations. Specifically, for example... Figures 1-5As shown, after the steel pipe pile 1 is driven and passes inspection and acceptance, a floating crane is used to lift the clamp-type pile cutting platform to the location of the steel pipe pile 1 to be treated. The platform consists of a frame body, clamps 4, water-retaining plate structure 2, water-stop pad 3, drainage pump pit 5, water pump 6, drainage pipe 7, pin beam 8, pin beam sleeve 9, hydraulic telescopic rod 10, oil delivery pipe 11, ladder 12, lifting point 13, merging and connecting edge 15, and oil pump 16. The frame body is divided into two semi-circular structures, which are initially connected by high-strength bolts. The operators guide the platform from top to bottom into the steel pipe pile 1 through the work boat, so that the lower edge of the platform bottom plate is aligned with the preset installation elevation line on the pile body. The oil pump 16 is started, providing power to the hydraulic telescopic rod 10 through the oil delivery pipe 11. This drives the pin beam 8 to extend and retract within the pin beam sleeve 9, allowing the semi-circular structures on both sides of the platform to form a rigid connection through the merging and intersecting edges 15. Then, the high-strength bolts of the clamp 4 are tightened, using the static friction between the clamp 4 and the steel pipe pile 1 to firmly fix the platform. The water-retaining plate structure 2 and the water-stop pad 3 are sealed together to prevent seawater infiltration. Next, the water pump 6 in the drainage pump pit 5 is started, pumping the seawater inside the platform to the sea surface through the drainage pipe 7, creating a dry working space. Operators enter the platform working area via the ladder 12, and using a total station with the shore control network as a reference, accurately measure and mark the design pile top elevation on the steel pipe pile 1.

[0021] like Figure 6 As shown, a hydraulic diamond wire saw or high-pressure water jet cutting device is then used to cut the steel pipe pile 1 around the marked line. The platform provides stable reaction support for the equipment, preventing the cut surface from tilting due to waves. After cutting, the cut pile head section is lifted away and transported by a floating crane. Then, keeping the platform fixed, the operators perform surface treatment on the cut surface and the area of ​​damage to the anti-corrosion coating caused by the platform clamping, using power tools to grind to the specified cleanliness and roughness. Subsequently, underwater curing epoxy resin coating is applied to ensure that the dry film thickness meets the design requirements, forming a continuous anti-corrosion barrier. After the anti-corrosion coating passes inspection, the oil pump 16 is started to drive the hydraulic telescopic rod 10 to retract, causing the pin beam 8 to disengage from the pin beam sleeve 9, the high-strength bolts of the clamp 4 are loosened, and the clamp-type pile cutting platform is lifted away by the floating crane through the lifting point 13, and the above operation is repeated for the next steel pipe pile 1 until all pile tops are treated to a uniform design elevation.

[0022] S2. Design and manufacture fully prefabricated longitudinal and transverse beams and fully prefabricated cantilever structures according to the drawings. The cross-sectional height of the fully prefabricated longitudinal and transverse beams is greater than the final design height. The excess part also serves as the permanent lateral formwork for subsequent cast-in-place concrete and is pre-embedded with shear reinforcement. This step is the core foundation of prefabricated construction. Through integrated structure-formwork design, fully prefabricated longitudinal and transverse beams and fully prefabricated cantilever structures are mass-produced in a land-based prefabrication yard, ensuring that the quality of the components is superior to that of offshore cast-in-place construction. Specifically, for example... Figure 7 and Figure 8As shown, firstly, based on the construction drawings, fully precast longitudinal and transverse beams and fully precast cantilever structures are designed. The cross-sectional height of the fully precast longitudinal and transverse beams is higher than the design height of the final formed beam. The excess portion (the formwork section) serves as permanent lateral formwork for subsequent cast-in-place concrete during the construction phase, eliminating the need for additional offshore formwork. Shear studs or short steel bar ends (shear-resistant steel bars) are pre-embedded in the formwork section to ensure a rigid connection with the cast-in-place joint area concrete. Then, high-strength steel molds are used, with the mold cavity height matching the cross-sectional height of the fully precast longitudinal and transverse beams. Positioning slots are installed on the mold side plates at positions corresponding to the final beam height to form the concrete construction joint interface. The mold dimensional error is strictly controlled within ±5mm to ensure component production accuracy. Next, epoxy-coated steel bars, cut to a fixed length and bent, are tied on a special jig to form the steel reinforcement skeleton of the fully precast longitudinal and transverse beams and the fully precast cantilever structure. Simultaneously, lifting rings, temporary supports, and embedded parts required for equipment installation are precisely pre-embedded, ensuring that the pre-embedded position deviations meet design requirements. Then, C50-C60 high-performance marine concrete is used, which is centrally mixed by an automated mixing plant and then evenly poured into the mold by a placing boom; the frequency conversion vibration platform is started to fully vibrate the concrete to ensure that there are no defects such as honeycomb or pitting in the densely reinforced areas.

[0023] After pouring, the components are placed in a constant temperature and humidity curing kiln for steam curing until the concrete strength reaches 100% of the design strength. Then, the molds are removed. The demolded components are numbered and visually inspected, with a focus on verifying the smoothness and flatness of the precast longitudinal and transverse beams and the mold surface. Qualified components are stored on wooden blocks in the precast yard's storage area. The qualified precast longitudinal and transverse beams and precast cantilever structures are transported to the construction site by barge. During transport, flexible padding is used to wrap the corners of the components to prevent collision damage.

[0024] S3. Connect friction clamps to the cut steel pipe piles. A water-stop pad is provided on the inner side of the friction clamps. An I-beam of the construction platform is erected on the connecting seat on the outer side of the friction clamps to form a friction clamp construction platform. This step aims to establish a stable offshore operating platform, providing a safe working surface for the hoisting of prefabricated components and the construction of key nodes. The platform is fixed to the steel pipe piles 1 via friction clamps 17, eliminating dependence on the vessel. Specifically, as shown... Figures 9-12 As shown, firstly, surveyors used a total station, with the shore control network as a reference, to measure and mark the installation elevation line of the friction clamp 17 on the completed steel pipe pile 1. Then, a floating crane was used to vertically lift the two semi-circular friction clamps 17, guiding the clamps to be smoothly fitted into the steel pipe pile 1, so that the bottom of the friction clamp 17 was aligned with the elevation line; high-strength bolts were inserted and initially hand-tightened, so that the water-stopping pad 3 on the inner side of the friction clamp 17 made initial contact with the surface of the steel pipe pile 1.

[0025] Then, using a calibrated hydraulic torque wrench, apply the design torque gradually in 2-3 stages, following the sequence of "first the middle, then both ends, and diagonally synchronously," to ensure that the friction clamp 17 is tightened evenly and forms a tight fit with the steel pipe pile 1. Finally, the static friction force between the friction clamp 17 and the pile body is not less than 2.5 times the maximum vertical load of the platform (including the structural self-weight and construction load). Add a pile clamping timber 21 between the friction clamp 17 and the steel pipe pile 1, and install a transverse pile clamping channel steel 22 on the outside to further enhance the fixing stability.

[0026] The longitudinal beams of the construction platform I-beams 19 are hoisted onto the connecting seat 18 on the outside of the friction clamp 17. After the longitudinal beams are in place, they are temporarily fixed with steel wedges to prevent lateral slippage. Then, perpendicular to the longitudinal beams, the transverse beams of the construction platform I-beams 19 are laid at intervals of 0.8-1.2m. The two ends of the transverse beams are fixed to the longitudinal beams by welding or "U" bolts to form a grid beam system.

[0027] A 4mm thick embossed steel plate or 50mm thick scaffold board is laid on the crossbeam as a working panel to form a friction clamp construction platform 20; steel pipe guardrails and kickboards with a height of 1.2m are installed around the platform, and safety nets are hung to form a closed and safe working environment.

[0028] S4. The prefabricated longitudinal and transverse beams and the fully prefabricated cantilever structure produced in step S2 are hoisted to the construction platform using hoisting equipment; This step employs a hybrid lifting strategy, primarily using specialized offshore bridge-building machines and secondarily using large floating cranes. Adaptive solutions are selected based on the characteristics of the structural areas to ensure precise installation of prefabricated components. Specifically, for example... Figure 7 and Figure 13As shown, the main standard section of the dedicated offshore bridge erecting machine has a simple hoisting structure. The middle and rear outriggers of the machine are supported on the completed superstructure (or precast components), and secured by an adjustable support system to form a stable anchor point. The front outrigger extends forward to the unconstructed span, and its bottom sleeve-type transition section fits into the top of the front steel pipe pile 1. The inner diameter D of the front outrigger transition section is equal to the diameter d of the steel pipe pile 1 plus 100mm, absorbing pile position deviations. Large-tonnage leveling jacks inside the transition section automatically extend, contacting and pressing against the top of the steel pipe pile 1 at different heights, completing the outrigger leveling and ensuring the main beam of the bridge erecting machine is horizontal. The double-sided overhead cranes on the main beam of the bridge erecting machine move to above the transport barge, collaboratively lifting the fully precast longitudinal and transverse beams or the fully precast cantilever structure. The cranes carry the components longitudinally along the main beam to directly above the target span, where coarse positioning is performed using an integrated RTK-GPS positioning system and a total station. The position of the precast components is precisely adjusted using the X, Y, and Z three-way micro-adjustment devices on the crane, so that the embedded steel bars at the bottom of the components are accurately aligned with the connecting parts at the top of the steel pipe pile 1, with a positioning accuracy of ≤5mm. Then, the components are slowly lowered to the design elevation to complete the initial fixing. The above operation is repeated to install all the precast components in the span in sequence.

[0029] For large floating crane vessels lifting complex structures or areas inaccessible to bridge erecting machines, the operational window is selected during periods of low tide, wind speed <6, and wave height <1m, using a sea state forecasting and monitoring system. The floating crane vessel stabilizes its position using a multi-point anchoring system, and RTK-GPS beacons are installed on the prefabricated components, with the three-dimensional coordinates of the components displayed in real-time in the command center. The floating crane vessel's hook lifts the prefabricated component, and operators manipulate the hook based on real-time coordinate data to slowly bring the component closer to the design position. Just before the component is in place, a long guide rod is used to guide the pre-embedded reinforcing bars to connect, avoiding collisions with steel pipe piles or already installed components. Waiting for a moment when the hull is relatively stable during the wave cycle, the component is quickly lowered to the design elevation and secured with temporary supports, completing the installation.

[0030] S5. After the precast components are hoisted into place, the steel bars between the components are tied or welded, the joint formwork is installed, and then the concrete in the joint area is poured to form an integral structure. This step aims to achieve a rigid connection of prefabricated components, forming an integral load-bearing structure. This is accomplished using the friction clamp construction platform 20. Specifically, as follows... Figure 7 and Figure 12As shown, operators on the friction clamp construction platform 20 bind or weld the beam-end reinforcement bars of adjacent precast longitudinal and transverse beams and precast cantilever structures to ensure that the reinforcement connection strength meets the design requirements. After the reinforcement connection is completed, the joint template of the node area is installed, and the template fits tightly with the combined template section of the precast longitudinal and transverse beams to ensure a leak-proof seal. High-strength micro-expansion concrete is poured into the node area and compacted using an immersion vibrator. After pouring, it is covered with curing cloth for moisture curing until the concrete strength reaches more than 75% of the design requirements.

[0031] S6. Pour the surface concrete on the assembled superstructure and install the auxiliary facilities; This step is the final stage of construction, completing the installation of the wharf surface layer and ancillary facilities to ensure the wharf is functional. Specifically, such as... Figure 7 and Figure 14 As shown, after the concrete strength of the joint reaches the standard, the temporary supports and working panels of the friction clamp construction platform 20 are removed; surface reinforcement is tied to the assembled superstructure, with the reinforcement arrangement avoiding the reserved cable troughs and other locations. The surface concrete is poured, with some areas set at a 1% slope as designed to meet drainage requirements; after pouring, it is finished and covered with a curing agent to cure to the design strength. After the surface concrete strength reaches the standard, auxiliary facilities such as fenders and mooring bollards are installed, ensuring accurate installation positions and firm fixation; finally, a comprehensive inspection of the entire breakwater wharf structure is conducted, and it is put into use after passing acceptance. Example 2

[0032] This embodiment 2 provides a prefabricated construction system for the superstructure of a breakwater wharf that implements the construction method of embodiment 1. The system includes a fully prefabricated component system, a friction clamp platform system, a clamp-type pile cutting platform, and hoisting equipment. Among them, such as Figure 7 As shown in Figure 8, the precast longitudinal and transverse beams are cast using C50-C60 marine concrete. The cross-sectional height is greater than the final design height. The extended portion (the formwork section) serves as a permanent lateral formwork for subsequent cast-in-place concrete during the construction phase, eliminating the need for additional offshore formwork. Shear studs or short steel bar heads (shear-resistant steel bars) are pre-embedded in the formwork section to ensure a rigid connection with the cast-in-place joint area concrete. An epoxy-coated steel reinforcement skeleton is provided inside. The steel bars are cut to length, bent, and tied on a special jig. The components are pre-embedded with lifting rings and embedded parts required for equipment installation. The dimensional error is controlled within ±5mm. After demolding, the surface of the formwork needs to be tested for smoothness (≤3mm / 2m) and flatness (≤2mm / m).

[0033] The fully prefabricated cantilever structure is made of the same material as the fully prefabricated longitudinal and transverse beams, and is cast using steel molds with the same precision as the prefabricated longitudinal and transverse beams. The structural thickness is 225mm or 250mm according to design requirements, with protective chamfers at the edges. The bottom is pre-embedded with lapped steel bars that connect to the prefabricated longitudinal and transverse beams to ensure that it can work together with the main structure after assembly. The surface has grooves for docking with the prefabricated panels, and the groove depth matches the thickness of the prefabricated panels to achieve rapid panel positioning and installation.

[0034] Among them, such as Figures 9-12 As shown, the friction clamp platform system is a stable support carrier for offshore operations. Through the rigid fixation of friction clamps and steel pipe piles, a land-like working surface is constructed. It includes friction clamps 17, connecting seats 18, construction platform I-beams 19, construction platform 20, pile clamping timbers 21, and transverse pile clamping channel steels 22. The friction clamp 17 consists of two semi-circular steel clamps (material Q355B) connected by 8-12 sets of high-strength bolts. A 10-15mm thick neoprene rubber waterstop pad 3 is pasted on the inner side, which not only enhances the friction with the steel pipe pile 1, but also achieves sealing and waterproofing. A connecting seat 18 is welded to the outer side of the steel clamp. The connecting seat 18 is a channel steel structure, and the groove size matches the flange width of the I-beam 19 of the construction platform, which is used to bear the platform load. When tightening the high-strength bolts, the design torque should be applied in 2-3 times in the order of "first the middle, then the two ends, and diagonally synchronously" to ensure that the static friction between the friction clamp 17 and the steel pipe pile 1 is not less than 2.5 times the maximum vertical load of the platform.

[0035] The aforementioned connecting seats 18 are specifically welded to the outside of the friction clamps 17. Two connecting seats 18 are symmetrically arranged on each friction clamp 17, with the spacing matching the span of the longitudinal beams of the H-beams 19 of the construction platform. A limiting baffle is installed on the top of the connecting seat 18 to prevent lateral slippage of the longitudinal beams. Rubber buffer pads are pasted on the inner side of the baffle to prevent rigid collisions between the longitudinal beams and the connecting seats 18. The H-beams 19 of the construction platform include longitudinal beams and transverse beams, both made of H-beams. The longitudinal beams are erected on the connecting seats 18, with both ends secured to the limiting baffles of the connecting seats 18 by steel wedges. The transverse beams are laid perpendicular to the longitudinal beams, spaced 0.8-1.2m apart, and both ends of the transverse beams are fixed to the longitudinal beams by U-bolts or welding to form a grid beam system. The surface of the H-beams is coated with anti-corrosion paint to adapt to the marine environment.

[0036] The friction clamp construction platform 20 consists of a grid beam system of the construction platform I-beam 19 and a working panel. The working panel is made of embossed steel plate with a thickness of ≥4mm and is fixed to the crossbeam with self-tapping screws, with a gap of ≤5mm between the plates. The platform is surrounded by steel pipe guardrails with a height of ≥1.2m, the guardrail posts are spaced ≤1.5m apart, and a 180mm high kick plate is installed at the bottom. A dense safety net (mesh density ≥2000 mesh / 100cm²) is hung on the inside of the guardrail. Anti-collision corner guards (rubber material) are installed at the corners of the platform to prevent collisions during component hoisting.

[0037] In addition, the clamping timber 21 is made of hardwood (pine or oak, with a moisture content of ≤15%), and is installed in pairs between the friction clamp 17 and the steel pipe pile 1. Two to three sets of friction clamps 17 are installed on each side to enhance the friction coefficient and protect the anti-corrosion coating of the steel pipe pile 1. The transverse clamping channel steel 22 is No. 10 channel steel, symmetrically arranged on the outside of the friction clamp 17, and is connected to the steel hoop of the friction clamp 17 by bolts to form a lateral constraint on the friction clamp 17 and prevent it from deforming under horizontal load.

[0038] Among them, such as Figures 1-6 As shown, the frame body of the clamp-type pile cutting platform, clamp 4, drainage system, rigid connection mechanism and power and auxiliary components; The frame body consists of two semi-circular frame beams 14 connected by high-strength bolts. A working deck is located at the top of the frame beams 14, surrounded by a water-retaining structure 2. Water-stop strips are affixed to the inner side of the water-retaining plates. A drainage pump pit 5 is located at the bottom of the frame beams 14, with a waterproof coating on the inner wall to prevent seawater leakage. The clamps 4 are integrated with the frame body. Two semi-circular clamps 4 are welded to the inner side of each semi-circular frame beam 14, and elastic buffer material 3 is affixed to the inner side of the clamps 4 to prevent damage to the anti-corrosion coating of the steel pipe piles 1. The number of high-strength bolts on the clamps 4 is determined based on load calculations to ensure that the static friction between the clamps 4 and the steel pipe piles 1 is sufficient to support the platform and construction loads.

[0039] The drainage system includes a drainage pump pit 5, a water pump 6, and a drainage pipe 7. The water pump 6 is a submersible pump, fixed inside the drainage pump pit 5, and connected to the drainage pipe 7 via a flange. One end of the drainage pipe 7 extends to the sea surface below the outer side of the platform, and the other end is connected to the outlet of the water pump 6. A shut-off valve is installed on the pipeline to control the start and stop of drainage. A grating cover is installed on the top of the drainage pump pit to prevent debris from entering and clogging the water pump 6.

[0040] Meanwhile, the rigid connection mechanism consists of a pin beam 8, a pin beam sleeve 9, and a hydraulic telescopic rod 10. The pin beam 8 is a solid round steel with a chrome-plated surface to reduce friction during expansion and contraction. The pin beam sleeve 9 is a seamless steel pipe, welded to the merging and intersection edge 15 of the frame beam 14. Each semi-circular frame beam 14 is equipped with 2-3 sets of these sleeves, and dustproof sealing rings are installed at both ends of the sleeve. The hydraulic telescopic rod 10 is a double-acting hydraulic cylinder, with one end hinged to the frame beam 14 and the other end connected to the pin beam 8. By extending and contracting, the pin beam 8 moves in and out of the pin beam sleeve 9, achieving rigid connection or separation of the structures on both sides of the platform.

[0041] In this embodiment, the power and auxiliary components include an oil pump 16, an oil delivery pipe 11, a ladder 12, and lifting points 13. The oil pump 16 is an electric hydraulic pump, fixed on the frame beam 14, and connected to the hydraulic telescopic rod 10 through the oil delivery pipe 11 to provide power. The ladder 12 is a steel ladder, welded to the outside of the frame body, to facilitate operators to go up and down the platform. The lifting points 13 are lifting lugs, with two symmetrically distributed on each semi-circular frame beam 14, used for floating and lifting the platform.

[0042] Lifting equipment is the core tool for the installation of prefabricated components. It adopts a hybrid configuration of special offshore bridge erecting machines and large floating cranes, all of which are existing technologies, and is used to achieve precise lifting of components in different areas.

[0043] The main beam of the dedicated offshore bridge erecting machine adopts a box-type steel structure, with its length determined according to the span of the wharf (usually 20-30m). The main beam is equipped with double-sided overhead crane tracks. The surface of the main beam is fitted with windproof and anti-slip devices to adapt to offshore wind loads. Its outrigger system includes front, middle, rear, and auxiliary outriggers. The bottom of the front outrigger has a sleeve-type transition section containing four large-tonnage leveling jacks, which can automatically level to accommodate pile foundation deviations. The middle outrigger has a lateral movement mechanism that adjusts its lateral position hydraulically to accommodate the precast beam's top reinforcement arrangement. The rear and auxiliary outriggers have adjustable support pads at their bottoms to prevent damage to installed precast components. The overhead cranes are located on both sides, each equipped with two winches. A traveling mechanism is located at the bottom of the crane, allowing it to move along the main beam tracks. The cranes integrate an RTK-GPS positioning system and a total station, and are equipped with X, Y, and Z-axis micro-adjustment devices (hydraulic drive, micro-adjustment accuracy ±1mm) to achieve precise component alignment.

[0044] Large floating crane vessels with a lifting capacity of ≥200t are selected and equipped with DP (Dynamic Positioning) system or multi-point mooring system to ensure that the vessel's position deviation is ≤0.5m during operation. The vessel is equipped with a dedicated command room with a built-in three-dimensional coordinate display system for components, which receives real-time positioning data from RTK-GPS beacons on the prefabricated components. The hook is equipped with angle and weight sensors to prevent the components from tilting or being overloaded. Lifting auxiliary tools include long guide rods to guide the connection of embedded steel bars when the components are in place, avoiding collisions with steel pipe piles 1 or already installed components.

[0045] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method of fabricated construction of a superstructure of a quay wall, characterized in that, The method comprises the following steps: S1. After the steel pipe pile (1) is sunk, the pile head is cut to the design elevation by a hoop type pile cutting platform, and the pile top anticorrosive coating is repaired; the hoop type pile cutting platform comprises a frame body and a hoop (4) located at the middle part of the frame body, and the frame body is fixed to the outer side wall of the steel pipe pile (1) through the static friction force between the hoop (4) and the steel pipe pile (1); S2. The full-precast longitudinal and transverse beams and the full-precast cantilever structure are designed and produced according to the drawings, the cross-sectional height of the full-precast longitudinal and transverse beams is greater than the final design height, the excess part serves as a permanent lateral formwork for the subsequent cast-in-situ concrete, and the shear-resistant steel bars are pre-buried; S3. The friction hoop (17) is connected to the cut steel pipe pile (1), the inner side of the friction hoop (17) is provided with a water stop pad (3), and the construction platform I-beam (19) is arranged on the connecting seat (18) outside the friction hoop (17) to form a friction hoop construction platform (20); S4. The precast longitudinal and transverse beams and the full-precast cantilever structure produced in step S2 are hoisted to the construction platform (20) by hoisting equipment; S5. After the precast components are hoisted in place, the component-to-component steel bars are bound or welded, the joint formwork is installed, then the concrete is poured in the node area, and the overall structure is formed; S6. The surface layer concrete is poured on the assembled upper structure, and the auxiliary facilities are installed.

2. The method according to claim 1, wherein In the step S1, the hoop type pile cutting platform further comprises a drainage pump pit (5), a water pump (6) and a drainage pipe (7), the water pump (6) is arranged in the drainage pump pit (5), the water pump (6) is in communication with the drainage pipe (7), and the water pump (6) is used for draining the accumulated water in the frame body; The frame body comprises a frame beam (14) and a water baffle structure (2) arranged on the frame beam (14), and the water baffle structure (2) is in sealing cooperation with the water stop pad (3).

3. The method of claim 1, wherein the method further comprises: In the step S1, the hoop type pile cutting platform further comprises a latch beam (8), a latch beam sleeve (9) and an oil hydraulic telescopic rod (10), the latch beam (8) is driven to extend or retract in the latch beam sleeve (9) through the oil hydraulic telescopic rod (10), so that the structures on both sides of the platform are rigidly connected.

4. The method of claim 1, wherein the method further comprises: In the step S1, the pile head cutting adopts hydraulic diamond wire saw or high-pressure water jet cutting; when the anticorrosive coating is repaired, the damaged area is first polished by using a power tool, and then underwater curing type epoxy resin paint is applied.

5. The method of claim 1, wherein the method further comprises: In the step S2, the full-precast longitudinal and transverse beams and the full-precast cantilever structure are both C50-C60 marine concrete components, and are both formed by pouring through a steel mold, the mold size error is controlled within ±5 mm; the steel bars adopt epoxy coated steel bars, the components are demolded after being maintained at constant temperature and humidity until the design strength is 100%, and the smoothness and flatness of the full-precast longitudinal and transverse beams are detected after demolding.

6. The method of claim 1, wherein the method further comprises: In the step S3, the friction clamp (17) includes two semicircular steel clamps which are fastened by high-strength bolts, wherein the high-strength bolts are applied with design torque in the order of "first middle, then two ends, diagonal synchronization" in 2-3 times, so that the static friction force between the friction clamp (17) and the steel pipe pile (1) is not less than 2.5 times of the maximum vertical load of the friction clamp construction platform (20); the construction platform I-beam (19) includes longitudinal beams and transverse beams which are laid along the direction perpendicular to the longitudinal beams with a spacing of 0.8-1.2 m.

7. The method of claim 1, wherein the method further comprises: In the step S4, the hoisting equipment is a special offshore bridge machine or a large floating crane ship; When the special offshore bridge machine is used, the front support leg is provided with an adjustable transition joint with an inner diameter larger than the diameter of the steel pipe pile (1) by 100 mm, the middle support leg is provided with a transverse moving mechanism, and the bridge machine is integrated with an RTK-GPS positioning system with a positioning accuracy of ≤5 mm; When the large floating crane ship is used, the operation is carried out during the slack tide period, when the wind speed is less than 6 and the wave height is less than 1 m, and an RTK-GPS beacon is installed on the prefabricated component to assist positioning.

8. A quayside superstructure assembly system for implementing the method according to any one of claims 1 to 7, characterized in that The full prefabricated component system and the friction clamp platform system are included; The full prefabricated component system includes full prefabricated longitudinal and transverse beams and full prefabricated cantilever structures, the cross-sectional height of the full prefabricated longitudinal and transverse beams is greater than the final design height, and the excess part serves as a cast-in-place formwork and is pre-buried with shear reinforcement; The friction clamp platform system includes a friction clamp (17), a connecting seat (18), a construction platform I-beam (19), and a friction clamp construction platform (20), the inner side of the friction clamp (17) is provided with a water stop pad (3), the outer side is connected to the connecting seat (18), the connecting seat (18) is provided with the construction platform I-beam (19) and forms the friction clamp construction platform (20).

9. The quayside superstructure assembly system according to claim 8, characterized in that It also includes a clamp type pile cutting platform, which includes a frame body, a clamp (4), a drainage pump pit (5), a water pump (6), a drainage pipe (7), a bolt beam (8), a bolt beam sleeve (9), and an oil hydraulic telescopic rod (10); The frame body is fixed with the steel pipe pile (1) through the clamp (4), the bolt beam (8) is arranged in the bolt beam sleeve (9), and the oil hydraulic telescopic rod (10) drives the bolt beam (8) to extend or retract, so that the frame body is combined or separated; The clamp type pile cutting platform also includes an oil pump (16) and an oil liquid delivery pipe (11), the oil pump (16) provides power for the oil hydraulic telescopic rod (10) through the oil liquid delivery pipe (11).

10. The quayside superstructure assembly system according to claim 8, characterized in that The friction clamp platform system also includes a pile clamping wood (21) and a transverse pile clamping channel steel (22), the pile clamping wood (21) is arranged between the friction clamp (17) and the steel pipe pile (1), and the transverse pile clamping channel steel (22) is arranged on the outer side of the friction clamp (17).

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