Assembled culvert channel movable formwork system and prefabrication construction method

Abstract

The present invention belongs to the field of civil engineering technology. A mobile formwork system for an assembled culvert channel comprises a cushion beam, a first sliding vehicle, a second sliding vehicle, a side form, an inner form, an end form, a transport trolley and a lifting device; a plurality of the cushion beams are arranged in parallel side by side; a bottom form is arranged on the upper part of the first sliding vehicle; second sliding vehicles are correspondingly arranged on both sides of the first sliding vehicle, and the first sliding vehicle and the second sliding vehicle are arranged on the corresponding cushion beams and can reciprocate along the cushion beams; side forms are supported and arranged on the second sliding vehicle; the transport trolley is arranged on the cushion beam and is located on the outer side of one of the second sliding vehicles. Also disclosed are a horizontal prefabrication construction method for an assembled culvert channel and a vertical prefabrication construction method for an assembled culvert channel. The present application is easy to use, simple to make, reusable, has high promotion value, greatly improves the use effect, and helps to promote the further development of prefabricated component production lines.

Description

Technical Field

[0001] The invention belongs to the technical field of civil engineering, and in particular relates to a movable formwork system for an assembled culvert channel and a prefabrication construction method. Background Art

[0002] In recent years, standardized construction has been gradually implemented in highway construction to promote the standardization, regularization and refinement of industry construction and comprehensively improve the level of construction management. The centralized prefabrication and assembly production of culvert channel components has emerged. The assembled culvert channel can achieve a perfect combination of factory assembly prefabrication and on-site mechanized assembly construction. It is less affected by the climate and can be operated all-weather. At the same time, it shortens the construction period, reduces costs, is safer and more environmentally friendly, and has obvious technical and economic advantages.

[0003] However, after many observations, analyses and actual explorations, it was found that there are still some deficiencies and flaws in prefabricated culverts and channels. For example, in areas with high seismic resistance and weak foundations, prefabricated culverts and channels are usually designed to be prefabricated and assembled on site by setting sockets and spigots, connecting the ends of the sockets, tensioning the reinforcement, and filling the sockets with water-stop rubber strips. However, due to the weight, span and clearance of the segments, the segment length is usually small (mostly 2m), and some segments need to be prefabricated separately from the upper and lower segments, and the segment length is even smaller (less than 2m).

[0004] When a large number of segments of the same model are prefabricated and produced together, due to errors in template production and installation, the sockets and spigots may not fit completely together when the segments are installed, or the ends of the segments (sockets and spigots) may not be completely perpendicular to the axis of the culvert, i.e., poor matching. Similarly, when the upper and lower segments are prefabricated separately, similar problems also exist in the tongue and groove parts during installation. After tensioning, torsion, bending, and stress concentration will occur, causing local damage to the spigots, sockets, and tongue and groove parts, and uneven widths of the joints in the longitudinal and transverse directions, forming "steps" between the segments, reducing the waterproof ability and having a poor visual effect. Moreover, when the back of the platform is backfilled, this situation will be further aggravated and prominent due to mechanical vibration and extrusion.

[0005] When the vertical prefabricated segments are used, it is difficult to set up when the socket or socket is located at the bottom, and it is necessary to set up hanging points in two directions, which increases the difficulty of template installation. At the same time, when installing the vertical prefabricated segments, additional lifting equipment is required to flip the segments from vertical to horizontal, which requires a large investment and increases the difficulty of installation. It is difficult to implement and difficult to promote and apply.

[0006] Therefore, the common culvert and channel segment centralized prefabrication mostly adopts fixed pedestals, and gantry cranes are mostly used for lifting and transportation. As a result, the template turnover, assembly and disassembly, and steel frame placement require long lifting distances, inflexible turnover, slow speed, and the template system does not meet the modular requirements. Therefore, finding a fast, efficient, and highly reliable method and modular mold has become an important task before people, and the success of this innovation will play a huge role in promoting the construction of prefabricated bridges in my country. Summary of the invention

[0007] The purpose of the present invention is to provide a prefabricated culvert channel mobile formwork system and a prefabricated construction method in view of the above-mentioned problems and shortcomings. The system is easy to use, simple to manufacture, reusable, has high promotion value, greatly improves the use effect, and helps to promote the further development of the prefabricated component production line.

[0008] To achieve the above purpose, the technical solution adopted is:

[0009] A mobile formwork system for an assembled culvert passage comprises a cushion beam, a first sliding vehicle, a second sliding vehicle, a side form, an inner form, an end form, a transport trolley and a lifting device; a plurality of the cushion beams are arranged in parallel side by side; a bottom form is arranged on the upper portion of the first sliding vehicle; second sliding vehicles are correspondingly arranged on both sides of the first sliding vehicle, the first sliding vehicle and the second sliding vehicle are arranged on the corresponding cushion beams and can reciprocate along the cushion beams; side forms are supported and arranged on the second sliding vehicles; the transport trolley is arranged on the cushion beam and is located on the outer side of one of the second sliding vehicles.

[0010] The first sliding vehicle and the second sliding vehicle both include a plurality of support beams, connecting rods and a sliding drive unit. The support beams are arranged corresponding to the cushion beams, and support rollers are arranged at the bottom of the support beams; the connecting rods are connected and arranged between the plurality of support beams; and the sliding drive unit drives the support beams to reciprocate on the cushion beams.

[0011] Side baffles corresponding to the two sides of the cushion beam are arranged on the support beam, and positioning pins are also arranged between the support beam and the cushion beam.

[0012] A transverse movement unit and a side support unit are provided between the side mold and the second sliding vehicle; the transverse movement unit is used to drive the side mold to move laterally on the second sliding vehicle; the side support unit is used to support the side mold;

[0013] The transverse movement unit includes a transverse movement roller, an adjusting power push rod and a wooden wedge. The transverse movement roller is arranged at the inner bottom of the side mold; the adjusting power push rod is arranged between the outer side of the side mold and the second sliding vehicle; the wooden wedge is arranged at the outer bottom of the side mold; the side support unit is an adjusting screw, and the two ends of the adjusting screw are respectively hinged on the side mold and the second sliding vehicle.

[0014] It also includes a loading and unloading mold pulley, which includes a first loading and unloading mold pulley and a second loading and unloading mold pulley. The first loading and unloading mold pulley is supported by the cushion beam, and the second loading and unloading mold pulley is supported by a steel skeleton or a precast concrete segment.

[0015] The end mold and the side mold are provided with hanging points, and the hanging points include a mold box, a hanging ring and a notch. The mold box is in the shape of a triangular groove, and the notch of the mold box is fitted and fixed to the corresponding end surface of the end mold or the side mold; the hanging ring is arranged in the mold box; the notch is opened on the side wall of the mold box, and the lower end of the hanging ring passes through the notch and is connected to the corresponding steel bar skeleton.

[0016] The end mold includes a vertical prefabricated socket template, a vertical prefabricated socket template and a vertical prefabricated tongue and groove template; the vertical prefabricated socket template includes an outer mold top support beam, an inner mold top support beam and a socket groove plate, the socket groove plate is in a U-shaped groove shape, and wing plates are arranged on both sides of the socket groove plate, and the two wing plates are mounted on the outer mold top support beam and the inner mold top support beam; the vertical prefabricated socket template includes an outer mold top support beam, an inner mold top support beam, a socket groove plate and a pad plate, the socket groove The plate is in a U-shaped groove shape, and wing plates are arranged on both sides of the socket groove plate. The socket groove plate is buckled on the outer mold top support beam and the inner mold top support beam, and the pad plate top support is arranged at the lower part of the socket groove plate; the vertical prefabricated tongue and groove formwork includes an outer mold top support beam, an inner mold top support beam and a tongue and groove groove plate, the tongue and groove groove plate is in a V-shaped groove shape, and wing plates are arranged on both sides of the tongue and groove groove plate, and the wing plates of the tongue and groove groove plate are mounted on the outer mold top support beam and the inner mold top support beam.

[0017] The first sliding vehicle, the second sliding vehicle and the transport trolley are all driven by a winch, and a basic base is arranged at the lower part of the cushion beam.

[0018] A method for horizontal prefabrication of an assembled culvert channel utilizes the above-mentioned movable formwork system for the assembled culvert channel to carry out horizontal prefabrication of the culvert channel.

[0019] A method for vertical prefabrication of an assembled culvert channel utilizes the above-mentioned movable formwork system for the assembled culvert channel to carry out vertical prefabrication of the culvert channel.

[0020] The beneficial effects achieved by adopting the above technical solution are:

[0021] 1. The materials and equipment constituting the movable bottom mold and side mold of the present application can form a standardized product, which is easy to purchase or manufacture, convenient to process, quick to install and dismantle, reusable, easy to finalize and promote. The overall investment of the present application is small, the applicability is strong, and the benefits are obvious.

[0022] 2. The track layout of the mobile bottom mold, side mold, and transport trolley of the present application is flexible and versatile. The I-beam pads used as the track are parallel to each other and have the same top surface height. Their lateral spacing can meet the design size and construction requirements of the common prefabricated component inner mold and side mold. The pad layout of the transport trolley can meet the transportation requirements of components, templates, and steel skeletons. The track length can be determined according to the site layout and production scale.

[0023] 3. The basic unit of the mobile bottom mold and side mold in this application is a sliding car, which can be processed by channel steel and rollers, or modified by a standardized roller load-bearing trolley, and the length can be made according to needs. It can be used alone to move the inner mold in and out (depending on the lateral size of the inner mold, every 2 or more groups as support), or according to the lateral size of the inner mold and side mold, the pulley can be connected with rods to form a combined pulley, and the top surface is provided with connecting rods, upper steel plates, and support belts for adjusting screw rods to form a mobile bottom plate and side molds. The pulley can place the rollers on the track to travel, and can also move the rollers upward to support objects (such as moving the inner mold).

[0024] 4. The combination of the movable bottom mold and side mold of the present application is diverse and variable. One set can be set for each prefabricated segment to form a segmented overall prefabrication; it can also be combined longitudinally, with three sets forming a prefabricated unit, and each set of bottom plates is connected by pins for the aforementioned unit-type overall prefabrication; it can also be prefabricated in different ways, horizontally and vertically, with strong overall versatility, capable of assembly and assembly, and high flexibility.

[0025] 5. The mobile side formwork of the present application is composed of a combined pulley loaded with a segment prefabricated side formwork. When the segment is horizontally prefabricated, it can be promptly transferred to the next segment prefabrication site after the side formwork is detached from the segment side plate, with a fast turnover rate, thereby reducing the number of side formworks. The side plate combined pulley can also be used for the transportation of small objects, which is flexible and lightweight.

[0026] 6. The mobile formwork system for the assembled culvert passage of the present application can realize the horizontal segmented overall prefabrication method, and the order of installation and use of the end formwork is: the right end socket of the first section is translated to the left end socket of the second section (making the socket slightly smaller than the socket); the right end socket of the second section is translated to the left end socket of the third section (making the socket slightly smaller than the socket), which can ensure the accurate docking between the two sockets and the sockets in one unit, and is the same as the installation order, which can avoid the problems of displacement, torsion, steps in the joints, etc. after tensioning caused by the mixing of a large number of identical segments.

[0027] 7. The mobile formwork system for assembled culvert passages in this application can realize the horizontal unitized overall prefabrication method, and can be prefabricated in full section according to the installation sequence of the segments, so that the sockets and sockets between the segments can fit tightly and match strictly, and the force is evenly distributed during tensioning, which can effectively avoid the offset, torsion, stress concentration, damage to the sockets and sockets, and "steps" between the segments. When installing the side panels, a similar climbing formwork method is adopted, "climbing" in the horizontal direction, which can ensure that the ends between the segments are accurately matched, the joints are smooth, and avoid the joints being staggered and damaged due to mechanical vibration during the backfilling of the platform.

[0028] 8. The mobile formwork system for the assembled culvert passage of the present application can realize horizontal segmented prefabrication. The inner mold is easy to put in and move out, especially when prefabricating the lower end, which can be operated by a gantry crane. The inner mold can be removed at the same time as the side mold. The operation is simple, the turnover is fast, and the number of templates required is small.

[0029] The mobile formwork system for the assembled culvert passage in the present application can realize the tongue-and-groove method of horizontal segmented prefabrication. After the "V"-shaped formwork of the tongue and groove of the lower section of the segment is removed, it is transported to the upper section prefabrication site and placed between the inner and outer top support beams of the tongue and groove of the upper section corresponding to the number, which can make the upper and lower sections fit tightly at the tongue and groove position, thereby improving the installation effect.

[0030] 9. The mobile formwork system for assembled culvert passages in the present application can realize vertical segmented overall prefabrication. When the plug is at the bottom, a square steel is fixed on each side of the "︺"-shaped formwork as the top support beams of the inner and outer forms; the "︺"-shaped formwork is flipped 180º to become a "︹"-shaped formwork, and a "convex"-shaped pad is placed underneath to become a socket formwork, which is easy to convert, firmly supported, and well matched.

[0031] 10. The mobile formwork system for the prefabricated culvert passage of the present application can realize vertical segmented prefabrication, and can be configured with a mobile base plate as needed. The upper and lower sections of the same section can be prefabricated on the same mobile base plate, and the same formwork can be used at the tongue and groove position for matching prefabrication. It can also adopt a "partitioned, centralized" production method to improve efficiency.

[0032] 11. The mobile formwork system of the prefabricated culvert passage of the present application can realize the method of moving in and out the integral segment and the segmented upper segment inner formwork, and adopts pulley support, especially the pulley on the segment bottom plate adopts soft rollers, which avoids scratches on the concrete surface and deformation of the steel skeleton caused by dragging and sticking.

[0033] 12. The fixing and traction devices of the mobile bottom plate and the mobile side plate in the mobile formwork system of the prefabricated culvert passage of the present application are simple and easy to operate. The mobile bottom plate and the side plate can be conveniently combined, and can be prefabricated horizontally or vertically; they can be prefabricated in sections or in combination and matching, realizing a streamlined "production line prefabrication" method.

[0034] 13. The segment lifting point setting method of the mobile formwork system of the prefabricated culvert passage of the present application can conveniently place lifting rings on the side or end of the segment by using the mold box. After the mold is removed, the lifting rings are in the grooves on the side or end of the segment. The lifting points are reasonably stressed, which is conducive to flipping the vertical prefabricated segments to a horizontal position during installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings of the embodiments of the present invention, wherein the drawings are only used to illustrate some embodiments of the present invention, but not to limit all embodiments of the present invention thereto.

[0036] Figure 1 It is a schematic diagram of the lateral arrangement structure of the assembled culvert channel movable formwork system according to an embodiment of the present invention.

[0037] Figure 2 It is a schematic diagram of the plan layout structure of the assembled culvert channel movable formwork system according to an embodiment of the present invention.

[0038] Figure 3 It is a structural schematic diagram of the working state of the assembled culvert channel movable formwork system according to an embodiment of the present invention.

[0039] Figure 4 It is a schematic structural diagram of a vertical prefabricated socket template according to an embodiment of the present invention.

[0040] Figure 5 It is a schematic structural diagram of a vertical prefabricated socket formwork according to an embodiment of the present invention.

[0041] Figure 6 It is a schematic structural diagram of a vertical prefabricated tongue and groove template according to an embodiment of the present invention.

[0042] Figure 7 Schematic diagram of the structure of the working state of the inner mold being removed according to an embodiment of the present invention.

[0043] Figure 8 FIG. 1 is a schematic diagram of the structure of a suspension point according to an embodiment of the present invention.

[0044] Fig. 9 This is a second structural schematic diagram of a suspension point according to an embodiment of the present invention.

[0045] Serial number in the picture:

[0046] 100 is the cushion beam, 110 is the foundation base;

[0047] 210 is a first sliding carriage, 211 is a support beam, 212 is a connecting rod, 213 is a winch, 214 is a support roller, 216 is a positioning pin, 220 is a second sliding carriage, 231 is a transverse roller, 232 is a wooden wedge, 233 is an adjusting screw, and 241 is a support belt;

[0048] 310 is a first mold loading and unloading pulley, and 320 is a second mold loading and unloading pulley;

[0049] 401 is a mold box, 402 is a hanging ring, and 403 is a notch;

[0050] 501 is the outer mold top support beam, 502 is the inner mold top support beam, 503 is the spigot groove plate, 504 is the socket groove plate, 505 is the pad plate, and 506 is the tongue and groove groove plate;

[0051] 601 is the side mold, 602 is the inner mold;

[0052] 710 is the transport trolley and 720 is the lifting equipment;

[0053] 801 is the upper section of the prefabricated segment, 802 is the lower section of the prefabricated segment, 803 is the socket, 804 is the spigot, 805 is the hanging point, 806 is the cable, and 807 is the pad. DETAILED DESCRIPTION

[0054] The following will be combined with the drawings of specific embodiments of the present invention to clearly and completely describe the exemplary scheme of the embodiment of the present invention. Unless otherwise defined, the technical terms or scientific terms used in the present invention should be the common meanings understood by people with ordinary skills in the field.

[0055] In the description of the present invention, it should be understood that the expressions “first” and “second” are used to describe the various elements of the present invention and do not represent any limitation of order, quantity or importance, but are only used to distinguish one component from another.

[0056] It should be noted that when one element is “connected”, “coupled” or “connected” to another element, it may mean that they are directly connected, coupled or connected, but it should be understood that there may be intermediate elements between the two; that is, the positional relationships of direct connection and indirect connection are covered.

[0057] It should be noted that the use of "a" or "an" and similar words does not necessarily indicate a quantitative limitation. "Include" or "comprising" and similar words mean that the elements or objects preceding the word include the elements or objects listed after the word and their equivalents, but do not exclude other elements or objects.

[0058] It should be noted that terms such as "up", "down", "left" and "right" indicating orientation or positional relationship are only used to indicate relative positional relationship. This is for the convenience of describing the present invention and does not mean that the device or element must have a specific orientation, be constructed and operated in a specific orientation. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0059] See also Figure 1-Figure 9 The present application discloses a mobile formwork system for an assembled culvert passage, comprising a cushion beam 100, a first sliding trolley 210, a second sliding trolley 220, a side form 601, an inner form 602, an end form, a transport trolley 710 and a lifting device 720; a plurality of cushion beams 100 are arranged in parallel side by side; a bottom form is arranged on the upper part of the first sliding trolley 210; second sliding trolleys 220 are correspondingly arranged on both sides of the first sliding trolley 210, and the first sliding trolley 210 and the second sliding trolley 220 are arranged on the corresponding cushion beam 100 and can reciprocate along the cushion beam 100; side forms 601 are supported and arranged on the second sliding trolley 220; the transport trolley 710 is arranged on the cushion beam 100 and is located on the outer side of one of the second sliding trolleys 220.

[0060] The first sliding vehicle and the second sliding vehicle both include a plurality of support beams 211, a connecting rod 212 and a sliding drive unit. The support beams 211 are arranged corresponding to the cushion beams 100, and support rollers 214 are arranged at the bottom of the support beams 211; the connecting rods 212 are connected and arranged between the plurality of support beams 211; the sliding drive unit drives the support beams 211 to reciprocate on the cushion beams 100. In this embodiment, the first sliding vehicle 210, the second sliding vehicle 220 and the transport trolley 710 are all driven by the winch 213, and a basic base 110 is arranged at the bottom of the cushion beam 100 to ensure the level of the entire formwork system.

[0061] Side baffles corresponding to the two sides of the cushion beam are arranged on the support beam 211, and positioning pins 216 are also arranged between the support beam and the cushion beam, wherein the side baffles can prevent the support beam from deviating from the cushion beam, and lateral support wheels can also be arranged on the side baffles to achieve support positioning in two directions. The function of the positioning pins is to achieve the alignment and fixation of the support beam and the cushion beam, and the positioning and locking of the support beam on the cushion beam can also be achieved by arranging other braking or locking structures, such as setting a limit block on the cushion beam to prevent the movement of the support roller.

[0062] In order to facilitate the adjustment and unloading of the side mold and ensure the stability of the side mold, a transverse movement unit and a side support unit are arranged between the side mold and the second sliding cart in this embodiment; the transverse movement unit is used to drive the side mold to move laterally on the second sliding cart; the side support unit is used to support the side mold; specifically, the transverse movement unit includes a transverse movement roller 231, an adjusting power push rod and a wooden wedge 232, the transverse movement roller 231 is arranged at the inner bottom of the side mold 601 (the side of the side mold close to the first sliding cart is the inner side); the adjusting power push rod is arranged between the outer side of the side mold and the second sliding cart; the wooden wedge 232 is arranged at the outer bottom of the side mold 601; the side support unit is an adjusting screw 233, and the two ends of the adjusting screw 233 are respectively hinged on the side mold 601 and the second sliding cart 220.

[0063] During the prefabrication construction process, it is also necessary to install and disassemble the inner mold. During the process of installing and disassembling the inner mold, there is a problem of difficulty in lifting, especially when a horizontal prefabrication method is adopted, it is easy to cause mechanical wear to the prefabricated segment; therefore, the present embodiment also provides a loading and unloading mold pulley, which includes a first loading and unloading mold pulley 310 and a second loading and unloading mold pulley 320. The first loading and unloading mold pulley 310 is supported on a cushion beam, and the second loading and unloading mold pulley 320 is supported on a steel skeleton or a concrete prefabricated segment. During the process of installing and disassembling the inner mold, the movement of the inner mold is achieved through the cooperation of the first loading and unloading mold pulley and the second loading and unloading mold pulley.

[0064] In order to facilitate the lifting of the prefabricated segments, lifting points are provided on the end mold and the side mold, and the lifting points include a mold box 401, a lifting ring 402 and a notch 403. The mold box 401 is in the shape of a triangular groove, and the notch of the mold box 401 is fitted and fixed to the corresponding end surface of the end mold or the side mold; the lifting ring 402 is arranged in the mold box 401; the notch 403 is opened on the side wall of the mold box 401, and the lower end of the lifting ring 402 passes through the notch 403 and is connected to the corresponding steel bar skeleton, so that the prefabricated concrete segment can have a corresponding lifting position, and has good bearing performance and stable structure.

[0065] The end mold includes a vertical prefabricated socket template, a vertical prefabricated socket template and a vertical prefabricated tongue and groove template; the vertical prefabricated socket template includes an outer mold top support beam 501, an inner mold top support beam 502 and a socket groove plate 503, the socket groove plate 503 is in a U-shaped groove shape, and wing plates are arranged on both sides of the socket groove plate 503, and the two wing plates are built on the outer mold top support beam 501 and the inner mold top support beam 502; the vertical prefabricated socket template includes an outer mold top support beam 501, an inner mold top support beam 502, a socket groove plate 504 and a pad plate 505, the socket groove plate 50 4 is in a U-shaped groove shape, and wing plates are arranged on both sides of the socket groove plate 504. The socket groove plate 504 is buckled on the outer mold top support beam 501 and the inner mold top support beam 502, and the pad plate 505 is top-supported and arranged at the lower part of the socket groove plate 504; the vertical prefabricated tongue and groove formwork includes the outer mold top support beam 501, the inner mold top support beam 502 and the tongue and groove groove plate 506. The tongue and groove groove plate 506 is in a V-shaped groove shape, and wing plates are arranged on both sides of the tongue and groove groove plate 506. The wing plates of the tongue and groove groove plate 506 are laid on the outer mold top support beam 501 and the inner mold top support beam 502.

[0066] The present application also discloses a method for horizontal prefabrication of an assembled culvert channel, which utilizes the above assembled culvert channel movable formwork system to carry out horizontal prefabrication of the culvert channel.

[0067] The present application also discloses a method for vertical prefabrication of an assembled culvert channel, which utilizes the assembled culvert channel movable formwork system to carry out vertical prefabrication of the culvert channel.

[0068] For the above specific structure, the specific production and implementation are described in detail:

[0069] The assembled culvert channel mobile formwork system of the present application is mainly composed of a cushion beam, a support beam, rollers, a connecting rod, an upper steel plate, a support belt, a screw rod, a pulley, a pin, a light winch, and a transport trolley.

[0070] On the concrete foundation pedestal or concrete floor of the site, a certain number of parallel I-beams of appropriate models with equal top heights are set as cushion beams. The transverse spacing of the I-beams meets the design size and construction requirements of the inner and side molds of the prefabricated components. The cushion beams of the transport trolley are arranged to meet the transportation requirements of the components, molds, and steel skeletons. The length of the cushion beams is determined according to the site layout, such as Figure 1 and Figure 2 shown.

[0071] Select a channel steel of suitable model and length (meeting the requirements of template assembly and disassembly), and the net height between its two limbs is slightly larger than the net width of the I-beam. Install a set of high-strength steel wheels (i.e., support rollers) between the two limbs of the channel steel, with the bottom surfaces of the support rollers at the same height, and the number of rollers meeting the load requirements, so that the movement is stable. This constitutes the basic component of the mobile bottom form and mobile side form - the pulley. The pulley is "inverted" on the top surface of the cushion beam, and the top surface of its two limbs is 10 to 20 mm lower than the top surface of the cushion beam, which plays a limiting role. The pulley can also use a standard part - a load-bearing roller trolley with an appropriate load capacity, and add side baffles or side baffle wheels on the side.

[0072] The specific structural arrangement of the second sliding vehicle is as follows: connecting rods of suitable size (such as two "back-to-back" angle steels) are fixed laterally to the top surfaces of two adjacent support beams at appropriate intervals; the gap between the two angle steels forms a limiting channel, which serves as a limiting channel for the transverse roller or transverse bearing at the bottom of the component side mold when traveling; steel plates of appropriate width and thickness are welded to the bottom of the two angle steels to serve as the traveling support track for the transverse roller and to support the weight of the side mold, thereby forming the second sliding vehicle to form a mobile side mold. The number and spacing of the connecting rods here depend on the structure of the side plates.

[0073] The specific structural arrangement of the first skid trolley is as follows: connecting rods (square steel of appropriate model and length) are welded or bolted to the sides of two adjacent pulleys at appropriate intervals, and the top surface is flush with the top surface of the pulleys. During the fixing process, wires are pulled for leveling, and a high-precision level or laser projector is used to ensure that the top surface of the first skid trolley is flat. If the spacing between the connecting rods is large, the upper steel plate is prone to downward deformation. The connecting rods can be appropriately increased, or vertical square steel can be welded between the two connecting rods. The top surface is flush with the large surface, and the upper steel plate here can be used directly as a bottom mold.

[0074] After the first skid is connected as a whole, install the upper steel plate as the bottom surface of the prefabricated component. Before installing the upper steel plate, use a high-precision level to level the entire plate or a laser projector to position it. For the lower position, fill the steel plate with a thin steel plate to adjust it. Drill holes on the steel plate with appropriate horizontal and vertical spacing, avoid the corresponding support rollers, drill through the top surface of the channel steel, and drill through the top surface of the square steel at the connecting rod. Drive aluminum rivets into the holes, and the top surface is level with the steel plate. To prevent the steel plate from partially bulging, drive the rivets from the inner layer to the outer layer.

[0075] Through the arrangement of the first sliding vehicle and the second sliding vehicle, a movable bottom mold and a movable side mold of the prefabricated component are formed.

[0076] An angle steel of suitable type is installed longitudinally on the outside of the second sliding vehicle to support the prefabricated side plate of the component. The angle steel is arranged on the top surface of the corresponding connecting rod. An angle steel of suitable type is installed longitudinally at an appropriate height on the outside of the side mold to support the prefabricated side plate of the component. The angle steel is arranged at the outer end of the side mold. The two angle steels are both support belts for fixing the side mold. An adjustment screw is arranged. The two ends of the adjustment screw are fixed on the upper and lower support belts. The position of the side mold is adjusted by rotating the screw. Specifically, according to the end size of the adjustment screw, triangular steel plates are welded in pairs at appropriate positions of the support belt, holes are drilled on the side, and holes are also drilled at the end of the screw, and pins or bolts are passed through to fix the adjustment screw.

[0077] The side mold of the prefabricated part is supported on the second sliding vehicle through the side mold frame. A transverse roller or bearing is installed at the bottom near the inner mold, and a pair of wooden wedges are used to support the bottom of the outer side of the side mold frame. The relative position and inclination of the side mold and the inner mold are adjusted by adjusting the screw rod, and the wooden wedges are used to fix them. When dismantling the side mold, the wooden wedges are removed, the side molds are pulled apart with the screw rod, and then the second sliding vehicle is moved longitudinally.

[0078] In order to simply and effectively fix the movable bottom formwork and side formwork, drill holes at the appropriate position (top surface of the channel steel) at the end of each support beam, avoiding the position of the support roller, passing through the top surface of the cushion beam (top surface of the I-beam), and set marks on the top surface of the cushion beam, and then insert the pins into the drilled holes.

[0079] In order to move the side plate or bottom plate conveniently and quickly, a hanging point is set at the front, rear end or side of the bottom formwork and side formwork of each segment with short ribs, bolts, etc., and a light winch can be hung. The hook at the end of the winch cable can be hung on a suitable hanging point in the front or rear (which can be set on the side of the cushion beam, the template of the front and rear segments, etc.), and the winch is driven to pull the bottom plate and side plate forward and backward. Similarly, the same structural design can be made on the transport trolley to facilitate the operation and driving of the trolley.

[0080] When the culvert (passage) segment adopts the horizontal prefabrication scheme, in order to facilitate the movement of the inner mold in and out, and to avoid the common problem of sticking, rubbing, and damaging the concrete surface due to dragging when the inner mold of the common box-type component is moved out, resulting in poor appearance, a special pulley and removal plan are manufactured.

[0081] A certain number of small pulleys are prepared, which can be divided into the first loading and unloading mold pulley and the second loading and unloading mold pulley. The first loading and unloading mold pulley placed at the front end has a length of 0.3-0.5m, and the height (from the bottom surface of the support roller to the top surface of the support beam + the height of the pad) is (the height of the mobile bottom plate pulley) + (the thickness of the upper steel plate of the mobile bottom plate) + (the thickness of the culvert bottom plate) + (the appropriate lifting height). The height of the second loading and unloading mold pulley placed at the rear end for supporting the inner mold to walk is appropriately smaller than the lifting height of the inner mold, and the roller of the second loading and unloading mold pulley is a soft rubber wheel with a length of 0.3m, which is convenient for placement and removal. The height difference between the first loading and unloading mold pulley and the second loading and unloading mold pulley is adjusted with pads.

[0082] When removing the inner mold, first loosen the supporting screw of the inner mold (folding inner mold) to fold it along the hinge point, so that the top surface falls down and the side surfaces shrink inward, reducing the cross section. For the shrinking inner mold, rotate the supporting screw to shrink the top and side surfaces inward, reducing the cross section.

[0083] First, lift the front and rear ends of the inner mold at the same time (using a gantry crane or jack), place the second mold loading and unloading pulley at the bottom of the rear end of the inner mold. To maintain walking stability, place 2 or 3 pulleys, lower the rear end so that its bottom surface is supported on the second mold loading and unloading pulley, loosen the rear end hook, start the gantry crane or winch, pull the inner mold out a section, and then place 2 groups (2-3 pulleys in each group) of the first mold loading and unloading pulleys with pads on the bottom of the inner mold in a front-to-back order (no pads are added to the top surface of the rear pulley for the time being), operate the gantry crane to make it fall on the pads, and continue to drive the gantry crane or winch. When the pulley supporting the rear end of the inner mold approaches the end, stop pulling, lift the inner mold, add pads to the first mold loading and unloading pulley at the back, so that its top surface is slightly higher than the second mold loading and unloading pulley supporting the inner mold in the segment. Drop the inner mold, continue to pull forward, and move the second mold loading and unloading pulley out at the same time.

[0084] Operation of moving the inner mold in: For horizontal integral prefabrication construction, first install the steel skeleton in place as a whole. When installing the steel bars, set an appropriate amount of supporting short bars to maintain the integrity of the skeleton. Place two second loading and unloading mold pulleys at both ends of the skeleton, with the rollers facing up and the top surface placed on the upper steel mesh of the segment bottom plate, at an appropriate distance from the end. Place the two ends of the inner mold in the contracted state on the top of the first loading and unloading mold pulley respectively, and the end that enters the inner mold first is suspended in the air for an appropriate amount. Pull backward (relative to the direction of pulling out the inner mold), and when it approaches the steel skeleton, lift the front end of the inner mold and drop it on the second loading and unloading mold pulley. Operate the gantry crane or winch to continue pulling, and at the same time adjust the lateral position of the inner mold, lift both ends of the inner mold, take out the second loading and unloading mold pulley, and drop the inner mold.

[0085] The method for setting the segment hanging points is as follows: a certain number of mold boxes are prepared with thin steel plates, the sides are triangular, one side is open close to the template, and the four sides are bent outward appropriately, and the other four sides are closed. A slot is made on the inclined surface at the lower end to allow the eye reinforcement to pass through. During installation, the opening surface of the mold box is installed close to the side mold or end mold at the designed lifting ring position, and holes are drilled appropriately around the mold box and the template at the same time, and inserted and fixed with thin bolts. Pass the eye reinforcement through the slot to block the gap, and fix the other end to the reinforcement skeleton. When removing the side mold or end mold, pull out the thin bolts, remove the side mold or end mold, and then remove the mold box.

[0086] The above-mentioned assembled culvert channel movable formwork system is used to prefabricate the culvert channel. The specific construction steps are described in detail as follows:

[0087] 1. Layout of construction site

[0088] 1. Floor and foundation layout

[0089] According to the construction organization design, the ground in the site is leveled and compacted. Depending on its strength, a concrete floor is poured on the ground. A layer of stable granular material or brick slag base can also be added, and then concrete is paved. Add foundations within the pedestal range, at the door crane track, and at the transport trolley track, or appropriately thicken the floor concrete layer.

[0090] When pouring the floor or foundation, strictly control the elevation and flatness of the concrete top surface, and pre-embed the rail anchor steel bars or connecting bolts.

[0091] 2. Track layout

[0092] On the concrete foundation or concrete floor of the site, a certain number of I-beams of appropriate models parallel to each other and with the same top surface height are set as tracks (beams). The lateral spacing meets the design dimensions and construction requirements of the inner mold and side mold of the prefabricated component. The layout of the beams of the transport trolley meets the transportation requirements of the components, templates, and steel skeletons. The length of the beams is determined according to the layout of the site. When installing the track, the plane position of each beam is accurately released and accurately leveled. The actual position of the embedded anchor steel bars is placed on the bottom surface of the beam (I-beam) on site. Drill holes on site, remove the steel bars that are too offset and cannot be corrected, and drill holes in the concrete again. During installation, a high-precision level is used to accurately measure the elevation of the top surface of the I-beam. After adjustment, a unified elevation is determined. The I-beam and the steel bars are not fixed temporarily, and steel parts are used for temporary support. After the elevation is adjusted, the gap between the I-beam and the ground is filled with steel parts and high-grade mortar. Finally, the I-beam and the anchor steel bars are spot welded or connected with embedded bolts.

[0093] 3. Horizontal and vertical layout of prefabrication site

[0094] According to the construction organization design, the tracks of the first sliding vehicle are laid out horizontally, and the tracks of the second sliding vehicle are laid out symmetrically on both sides. The length of each segment track is the segment design length plus the appropriate support operation length. The horizontal width takes into account the template support and operation range to form a prefabricated segment. A gantry crane is laid out at an appropriate distance outside the side mold and is used as a lifting device. The span of the gantry crane is determined according to the prefabricated segment model of the left and right prefabricated pedestals and the setting of the intermediate transportation road. Its weight should meet the segment lifting and transportation requirements.

[0095] The layout of the transport trolley track is the same as above, and the track spacing meets the needs of the trolley to transfer prefabricated segments, steel skeletons, and formwork.

[0096] The site is arranged longitudinally. In addition to reserving space for steel bar processing and storage, formwork repair, and segment curing, the length of the prefabricated pedestal is determined according to the number of segment models, formwork turnover, and prefabrication method (segmented prefabrication or unit prefabrication, vertical prefabrication or horizontal prefabrication). The length of the transport trolley track (or road length) is determined according to the stage storage site and deadline.

[0097] 2. Layout of mobile bottom mold, mobile side mold and transport trolley

[0098] 1. Production of skid trolley and loading and unloading mold pulley

[0099] Select a channel steel of suitable model and length (to meet the requirements of template assembly and disassembly), with the net height between the two limbs slightly larger than the net width of the I-beam. Install a set of high-strength steel wheels (rollers) between the two limbs of the channel steel, with the bottom surfaces of the rollers at the same height, and the number of rollers meeting the load requirements, so that the movement is stable. This constitutes the basic component of the mobile bottom plate, mobile side plate and transport trolley - the pulley. The pulley is "inverted" on the top surface of the cushion beam, and the top surface of its two limbs is 10 to 20 mm lower than the top surface of the cushion beam, which plays a limiting role. The pulley can also use a standard part - a load-bearing roller trolley with an appropriate load capacity, and a limit steel plate is installed on the side.

[0100] The length of the pulley and the number of rollers should be based on the requirements of firm support, flexible walking, stable direction, and template assembly and disassembly. Test the walking stability and adjust the direction of the rollers to avoid the pulley deflecting during walking and causing friction between the two limbs of the channel steel and the two sides of the top surface of the I-beam.

[0101] The basic structure of the skid trolley is manufactured by the above-mentioned manufacturing method, and different templates are arranged on different skid trolleys to form a mobile bottom template or a mobile side template.

[0102] In addition to making the above-mentioned standard pulleys, a certain number of short, high-heightened steel wheel and rubber-wheel pulleys are also prepared. They are used for loading and unloading inner molds and transporting small objects. The rubber-wheel pulleys can run on tracks and can be flipped over with the rollers facing upwards to support heavy objects.

[0103] 2. Production of the first skid trolley and bottom mold

[0104] Fixing of the sliding compartment of the mobile bottom mold (fixing between multiple support beams): Use connecting rods (square steel of appropriate type) to be welded on the sides of two adjacent support beams at appropriate intervals, and its top surface is flush with the top surface of the sliding trolley. When welding the connecting rods, pull the wire for leveling, and use a high-precision level or laser projector to ensure that the top surface of the entire sliding trolley is flat. If the spacing between the connecting rods is large, the upper steel plate is prone to downward deformation. The connecting rods can be appropriately increased, or vertical square steel can be welded between the two connecting rods to make the top surface flush with the large surface.

[0105] After the supporting beams of the mobile bottom mold are connected as a whole, the upper steel plate is installed as the bottom surface of the prefabricated component. Before installing the upper steel plate, use a high-precision level to level the entire plate or a laser projector to position it. For the lower position, fill a thin steel plate under the steel plate to adjust it. Drill holes in the steel plate with appropriate horizontal and vertical spacing, avoid the rollers of the pulley, drill through the top surface of the channel steel, and drill through the top surface of the square steel at the connecting rod. Drive aluminum countersunk rivets into the holes, and the top surface is level with the steel plate. To prevent local bulges on the steel plate, drive the rivets from the inner layer to the outer layer. This constitutes a mobile modular bottom mold for the prefabricated component, that is, the first sliding car and the bottom mold arranged on the first sliding car are formed.

[0106] 3. Production of the second skid trolley and side mold

[0107] Connecting rods (two "back-to-back" angle steels) of appropriate size are fixed to the top surfaces of the two pulleys in the horizontal direction with appropriate spacing. The gap between the two angle steels is used to limit the movement of the rollers or bearings at the bottom of the side plate frame of the component. Steel plates of appropriate width and thickness are welded to the bottom of the two angle steels to support the weight of the side formwork, thereby forming a modular mobile side formwork, that is, forming an assembly structure of the second sliding vehicle and the side formwork arranged on the second sliding vehicle. Among them, the number and spacing of the connecting rods depend on the structure of the side formwork.

[0108] An angle steel of suitable type is installed longitudinally on the outer side of the movable side form to support the prefabricated side form of the component. The angle steel is arranged on the top surface of the connecting rod.

[0109] An angle steel of suitable type is installed longitudinally at an appropriate height on the outside of the side form frame to support the prefabricated side form of the component. The angle steel is arranged at the outer end of the side form frame and serves as a support belt together with the angle steel arranged on the top surface of the connecting rod to fix the side form.

[0110] The adjustment screw rod used to support the side mold is fixed on the upper and lower support belts. The position of the side mold is adjusted by rotating the screw rod. According to the size of the screw rod end, a triangular steel plate is welded in pairs at the appropriate position of the support belt, and a hole is drilled on the side. A hole is also drilled at the end of the screw rod, and a pin or bolt is passed through to fix the screw rod.

[0111] The side form frame of the prefabricated part has a transverse roller or bearing installed at the bottom near the inner form. A pair of wooden wedges are used to support the bottom of the outer side of the frame. The screw rod is used to adjust the relative position and inclination of the side form and the inner form, and it is fixed with wooden wedges. When dismantling the side form, the wooden wedges are removed, the side form is pulled open with a screw rod, and the side panel combination pulley is driven longitudinally. If the center of gravity of the side panel is high, it can be protected by hanging it in an appropriate position with a door when moving.

[0112] 4. Production of transport trolley

[0113] The manufacturing method and structure are basically the same as those of the first and second sliding carts. The upper steel plate can be replaced by a wooden board or a thickened steel plate, support belts are added around the top surface, and the connecting rods are strengthened.

[0114] 5. Fixing of the first skid trolley, the second skid trolley and the transport trolley

[0115] In order to simply and effectively fix the movable bottom formwork and side formwork, drill a hole at the appropriate position (top surface of the channel steel) at the end of each combined pulley, avoid the roller position, pass through the top surface of the pad beam (top surface of the I-beam), set a mark on the top surface of the pad beam, and insert the pin into the drilled hole.

[0116] 3. Horizontal prefabrication method

[0117] like Figure 3 As shown, ①②③④⑤ are the prefabrication order.

[0118] 1. Segmented overall prefabrication

[0119] It is suitable for segmented prefabrication of box culverts with small span and clearance.

[0120] (1) The size of the movable bottom mold and side mold is selected according to the size of the segment. Each segment is prefabricated separately. Each prefabricated segment has a set of inner molds. Every 2 to 3 prefabricated segments have a set of side panels. The number of end molds is determined according to the segment docking form (flat end or socket end) to meet the turnover requirements.

[0121] First, fix the bottom mold and side mold with pins.

[0122] like Figure 2 As shown, L1 is the bottom width of the prefabricated segment, and L2 is the bottom length of the prefabricated segment.

[0123] (2) Set up the side mold. Use a door crane to move the two side panels inward through the rollers or bearings on the side panel frame, and support the outside with wooden wedges. Place them accurately and support them on the side and upper support belts with adjusting screws.

[0124] (3) The reinforcement skeleton is in place. The reinforcement skeleton is made in an integrated manner in the reinforcement processing area. Support measures are taken during the lifting, transportation and placement process to reduce deformation. Roller-type high-strength pads are added to the bottom and sides to provide a protective layer. When installing the reinforcement, an appropriate amount of supporting short bars is set to maintain the integrity of the reinforcement skeleton.

[0125] (3) Move the inner mold in.

[0126] Place two second mold loading and unloading pulleys at appropriate positions at both ends of the steel skeleton, with the rollers facing up and the top surface placed on the upper steel mesh of the segment bottom plate. Place the two ends of the inner mold in the contracted state on the top of the first mold loading and unloading pulley respectively, and the end that enters the inner mold first is suspended in the air for an appropriate amount. Pull backward (relative to the direction in which the inner mold is pulled out), and when it approaches the steel skeleton, lift the front end of the inner mold and drop it on the second mold loading and unloading pulley. Operate the gantry crane or winch to continue pulling, and at the same time adjust the lateral position of the inner mold, lift both ends of the inner mold, take out the second mold loading and unloading pulley, and drop the inner mold. Adjust the inner mold support screw to open the folded or contracted part, press the steel skeleton pad, adjust the inner mold joint, seal the gap, install the end plate, and add pads to set the top plate steel protection layer.

[0127] The end setting method is as follows: the left end of the first prefabricated segment is a flat end and the right end is a socket end; the left end of the second prefabricated segment is a spigot end and the right end is a socket end; the left end of the third prefabricated segment is a spigot end and the right end is a flat end.

[0128] The order of installation and use of the end mold is: the socket at the right end of the first precast segment is translated to the socket at the left end of the second precast segment; the socket at the right end of the second precast segment is translated to the socket at the left end of the third precast segment.

[0129] (4) Remove the side formwork and end formwork. After the poured concrete reaches the specified strength, first remove the supporting wooden wedges at the outer end of the side panel frame, then loosen the adjusting screw, pull the side formwork outward to separate it from the corresponding segment side panel concrete, and remove the end panel at the same time. Loosen the positioning pins between the second skid trolley and the cushion beam, hang the light winch in the appropriate position, pull out the cable, hang the hook on the appropriate hanging point in front, drive the winch, and pull the second skid trolley and the side formwork forward to the next working surface.

[0130] (5) Remove the inner mold. After the concrete reaches the specified strength, first loosen the supporting screw of the inner mold (folding inner mold) to fold it along the hinge point, so that the top surface falls down and the sides shrink inward, reducing the cross-section. For the shrinking inner mold, rotate the supporting screw to make the top and sides shrink inward, reducing the cross-section.

[0131] First, lift the front and rear ends of the inner mold at the same time (using a gantry crane or jack), place the second mold loading and unloading pulley at the bottom of the rear end of the inner mold. To maintain walking stability, place 2 or 3 pulleys, lower the rear end of the inner mold so that its bottom surface is supported on the second mold loading and unloading pulley, loosen the rear end hook, start the gantry crane or winch, pull the inner mold forward for a section, and then place 2 groups (2-3 pulleys per group) of the first mold loading and unloading pulleys with pads in the front and back order at the bottom of the pulled inner mold (no pads are added to the top surface of the rear pulley for the time being), operate the gantry crane to make it fall on the pads, and continue to drive the gantry crane or winch. When the pulley supporting the rear end of the inner mold approaches the end, stop pulling, lift the rear end of the inner mold, add pads to the rear pulley, so that its top surface is slightly higher than the second mold loading and unloading pulley supporting the inner mold in the segment. Drop the inner mold, continue to pull forward, and move the second mold loading and unloading pulley out at the same time.

[0132] 2. Unitized overall prefabrication

[0133] When prefabricating segments on the pedestal, each prefabricated unit (every three prefabricated segments are tensioned once during installation) is equipped with three sets of inner molds (the length of the inner mold is the designed length of the prefabricated segment), one set of side molds (two pieces each of the designed prefabricated segment length and the designed prefabricated segment length + 0.5m), and one set of end molds (one piece each of the flat end and the socket end). The end mold can be stuck around the inner mold (the length of the inner mold is slightly greater than the designed length of the prefabricated segment) or the inner mold can be pressed against the end mold (the length of the end mold is equal to the designed length of the prefabricated segment). After the first prefabricated segment is prefabricated, its right end is used as the end template of the second prefabricated segment, that is, the socket at the right end of the first prefabricated segment is used as the end mold of the socket at the left end of the second prefabricated segment.

[0134] Before prefabricating the second prefabricated segment, a rubber strip with a suitable thickness and smooth surface is pasted on the upper and lower inclined surfaces of the right end of the first prefabricated segment. The thickness and hardness of the rubber strip should be such that the section of the prefabricated plug is appropriately smaller than the section of the socket and there is a certain adjustment range when the segment is installed. Spray a quick-drying isolation agent on the surface of the socket.

[0135] When installing the reinforcement and inner formwork of the second precast segment, the operation method is the same as that of the first precast segment. Keep an appropriate distance from the first precast segment that has been cast, do not fix the side formwork temporarily, and then drive the bottom and side plates to move, approach and press against the first precast segment.

[0136] When installing the side form of the second prefabricated segment, clamp the side of the first prefabricated segment by 0.5m, press the inner form against the inner form of the first prefabricated segment, and fill the gap between them.

[0137] After the concrete side formwork of the second precast segment is removed, two light winches are hung at appropriate positions on the ends of the first precast segment or the second precast segment, the cables are pulled out, the hooks are hung on appropriate hanging points, the positioning pins are pulled out, and the winches are driven to separate the two segments from the sockets and sockets. The pulling distance is based on the removal of the inner formwork.

[0138] The operation method for removing the inner mold is the same as before.

[0139] Through the above-mentioned prefabrication construction method, the movable bottom form and side form can be flexibly arranged, and the whole section can be prefabricated according to the installation sequence of the segments, so that the sockets and sockets between the segments can fit tightly and match strictly, and the force is evenly distributed during tensioning, which can effectively reduce the offset, torsion, stress concentration, damage to the sockets and sockets, and "steps" between the segments. When installing the side panels, a similar climbing formwork method is adopted, "climbing" in the horizontal direction, which can ensure that the ends between the segments are accurately matched, the joints are flat, and avoid the joints being staggered and damaged due to mechanical vibration during the backfilling of the platform.

[0140] 3. Segmented prefabrication

[0141] For segments with larger span and clearance, in order to facilitate prefabrication, transportation and installation, the segments are prefabricated into upper and lower sections and transported to the site for assembly.

[0142] (1) The prefabrication of the lower section of the segment is the same as the above-mentioned segmented overall prefabrication operation method. The difference is that the inner mold is easier to drop in and out, and can be operated by a gantry crane. In addition, the inner mold can be removed at the same time as the side mold, which has a faster turnover and requires fewer templates.

[0143] (2) The prefabrication of the upper section of the segment is the same as the above-mentioned segmented integral prefabrication operation method, the difference is that the inner mold can be put in place first, and the removal method is the same as before, which is relatively simpler than the above-mentioned method.

[0144] (3) Difficulties of prefabrication of segments. Since the segments are prefabricated in two parts, the inner mold is also divided into two parts, and the manufacturing error makes it difficult for the upper and lower segments to be vertically smooth during installation. At the same time, a horizontal joint - the tongue-and-groove joint - is added to the segment wall. In addition, the sockets and sockets at both ends of the segment are also divided into two parts, which increases the difficulty of docking during installation. It is easy for "steps" to appear between segments, the tongue-and-groove is not smooth, the longitudinal and transverse prestressed steel bars are bent, the friction resistance with the hole is increased, and the force is distorted. The appearance effect will also be unsatisfactory.

[0145] (4) The setting method of the segment end socket, socket and upper and lower tongue and groove template. The segment prefabrication adopts the "partitioning and centralization" method. The upper and lower segments are prefabricated in a centralized manner, with each three segments forming a unit.

[0146] The end settings of the upper and lower segments are: the left end of the first prefabricated segment is a flat end and the right end is a socket; the left end of the second prefabricated segment is a spigot and the right end is a socket; the left end of the third segment is a spigot and the right end is a flat end.

[0147] After the first prefabricated segment is prefabricated, the right end socket template is removed and installed horizontally at the left end of the second prefabricated segment as a spigot template, so that the spigot size is slightly smaller than the socket size.

[0148] After the second prefabricated segment is prefabricated, the right end socket template is removed and installed horizontally at the left end of the third segment as a spigot template, so that the spigot size is slightly smaller than the socket size.

[0149] The tongue and groove of the lower section of the segment is located at the upper part. After the "V"-shaped template of the tongue and groove is removed, it is transported to the prefabrication site of the upper section and placed between the inner and outer top support beams of the tongue and groove of the upper section corresponding to the number, to ensure that the upper and lower sections fit tightly at the tongue and groove position.

[0150] The production and installation of the inner molds of the upper and lower segments should ensure the corresponding accuracy. The dimensions should be accurate after the cross-sections are connected, and they should be numbered in pairs to avoid confusion and be calibrated regularly.

[0151] 4. Unitized segmented prefabrication

[0152] It is used for small sites where it is inconvenient to adopt the "zoning and centralized" production method. For segments with large spans and clear widths, inconvenient transportation and installation, and suitable for segmented prefabrication, it can take into account the matching issues of the segment's plugs, sockets, and tongues at the same time, making them fit tightly, which is more beneficial to ensuring the appearance effect after installation.

[0153] The setting of each prefabricated unit is the same as before, using an integral inner mold and a segmented side mold (divided into upper and lower parts by tongue and groove).

[0154] Construction sequence of the first precast segment: prepare the bottom formwork, erect the lower section side formwork → install the lower section steel bars → move in the inner formwork (gantry crane operation) → fix the side formwork and the tongue and groove top formwork → install the end formwork → pour the lower section concrete → remove the tongue and groove formwork and spray the isolation agent → remove the end formwork, spray the isolation agent on the socket and stick the rubber strip → install the upper section steel bars → install the upper section side formwork (supported on the upper section side formwork) and end formwork → pour the upper section concrete → remove the upper and lower section side formwork and the upper section end formwork → move out the inner formwork socket → spray the isolation agent on the socket and stick the rubber strip.

[0155] The length of the side form of the first prefabricated segment can be set to: segment design length + 0.5m. After being dismantled, when it is used as the side form of the second prefabricated segment, it is installed by clamping 0.5m of the side of the first prefabricated segment.

[0156] The construction sequence of prefabricated units is:

[0157] The lower section of the first prefabricated segment → the upper section of the first prefabricated segment and the lower section of the second prefabricated segment → the upper section of the second prefabricated segment and the lower section of the third segment → the upper section of the third segment → pull apart the segments → remove the inner mold.

[0158] According to this plan, for one prefabricated unit, the side mold is used three times, the flat end mold is used twice, the socket end mold is used once, and the three sections of the inner mold are used once each. The socket of the segment is pulled apart and the inner mold is removed in the same unit-type overall prefabrication method.

[0159] During the horizontal prefabrication of segments, due to the large area of ​​the segment bottom mold, in order to ensure the collapse and vibration effect of the bottom mold concrete, two holes can be opened at appropriate positions on the bottom surface of the inner mold (i.e. the top surface of the segment bottom plate), and movable elbows can be installed, which can be connected to the pump pipe of a small concrete delivery pump, and valves are installed at the elbow and the bottom plate opening. The small delivery pump can be placed on a transport trolley and moved between the working surfaces.

[0160] To prepare high-performance concrete, first use the pressure of the delivery pump with an attached vibrator installed on the inner mold bottom plate to quickly cast the segment bottom plate, close the valve in time, and then cast the side plates and top plate symmetrically from both sides.

[0161] For the following sections that use vertical prefabrication, the base plate may not be cast for the time being. The base plate can be cast on site after installation and then tensioned.

[0162] 5. Setting of hanging points

[0163] Use thin steel plates to prepare a certain number of mold boxes, with triangular sides, one side of the mold opening close to the template, and the four sides are bent outward appropriately, and the other four sides are closed. A slot is made on the inclined surface at the lower end to allow the eye reinforcement to pass through. During installation, install the mold box opening close to the side mold or end mold at the designed eye position, drill appropriate holes around the mold box and the template at the same time, and insert and fix it with thin bolts. Pass the eye reinforcement through the slot to block the gap, and fix the other end to the reinforcement skeleton. When removing the side mold or end mold, pull out the thin bolts, remove the side mold or end mold, and then remove the mold box.

[0164] 4. Vertical prefabrication method

[0165] Compared with the horizontal prefabrication method, the vertical prefabricated inner mold is simpler and easy to move in and out, which is conducive to mold placement and vibration when pouring concrete. The inner mold can be removed at the same time as the side mold, with a faster turnover, which can reduce the number of templates, and only requires a mobile bottom plate, which can save the mobile side plate. However, when the steel bars are put into the mold, a certain number of horizontal (segment horizontal direction) reinforcement bars need to be set on the segment steel skeleton, and hanging points need to be set in two directions - the segment side plate and the end to facilitate the segment flipping. When prefabricating in sections, it is difficult to match the socket, the socket, and the tongue and groove, especially some sockets and sockets, which need to be set on the prefabricated bottom plate, which is difficult to match, increases the difficulty of installation, and affects the visual effect. The segments can be placed vertically during transportation, but lifting equipment needs to be added during on-site installation to adjust the segments from vertical to horizontal.

[0166] 1. Segmented overall prefabrication

[0167] (1) Template configuration

[0168] Three prefabricated segments are used as a prefabricated unit, which is equipped with four side molds, a set of inner molds, two socket and plug templates. No flat template is required, and one end of the flat mouth can be placed on the prefabricated bottom plate.

[0169] (2) Template placement method

[0170] The first prefabricated segment has the flat end at the bottom and the socket at the top; the second prefabricated segment has the socket at the bottom and the spigot at the top; the third segment has the flat end at the bottom and the spigot at the top. Prefabricate and install in this order, and configure the movable bottom mold.

[0171] (3) Support scheme for socket, spigot, inner mold and side mold

[0172] The upper and lower ends of the segment template are set to be flat, and the plug and socket are set using a movable end template.

[0173] During vertical prefabrication, the socket and spigot at one end of the segment need to be installed on the prefabricated bottom mold. In order to prevent the socket and spigot from being damaged due to excessive pressure, a square steel is fixed on each side of the "︺"-shaped template of the spigot as the top support beams of the inner and outer molds. The two sides of the spigot template extend horizontally to an appropriate length and rest on the square steel, with the inner and outer molds close to their outer edges.

[0174] When the socket is set at the bottom, flip the "︺"-shaped template 180º to become a "︹"-shaped template, and place a "convex"-shaped pad plate underneath it. The inner and outer mold supports are the same as above.

[0175] (4) Prefabrication method

[0176] Clean the prefabricated bottom mold of the first prefabricated segment and install four side molds. Put the steel frame in place as a whole, hang the inner mold in a folded or contracted state into place, turn the support screw of the inner mold to make it close to the pad on the steel frame, install the "︺"-shaped socket template on the top surface, seal the gap with the prefabricated bottom plate, install the vibrator, and pour concrete.

[0177] Remove the "︺"-shaped socket template on the top surface of the first prefabricated segment in a timely manner, clean it and move it to the prefabrication site of the second prefabricated segment, flip the "︺"-shaped template 180º to a "︹" shape, place it on the inner and outer mold top support beams set on the prefabricated bottom plate, and place a "convex"-shaped pad plate underneath it to become the socket template of the second prefabricated segment. Remove the side mold and inner mold of the first prefabricated segment, clean it and move it to the prefabrication site of the second prefabricated segment. After the side mold, steel skeleton and inner mold are in place, install the "︹"-shaped socket template on the top surface (set as the lower end socket and the upper end socket), install the vibrator, and pour concrete. The second prefabricated segment can also be set as the lower end socket and the upper end socket.

[0178] Remove the end formwork, side formwork and inner formwork of the second prefabricated segment in a timely manner, clean the side formwork first, move it to the prefabrication site of the third segment and install it in place, then install the steel skeleton and inner formwork of the third segment, and finally install the “︹”-shaped socket formwork on the top surface (the third segment is set with a flat bottom and a socket at the top), install the vibrator and pour concrete.

[0179] In order to reduce leakage at the upper and lower ends of the segment, sealing strips can be pasted on the upper and lower ends of the inner and outer molds.

[0180] (5) Moving the inner mold in and out

[0181] Moving the inner mold in. After the side molds and steel frame are installed in place, the inner mold in a folded or contracted state is hoisted and dropped inside the steel frame to support the middle frame to facilitate the movement of the surrounding side panels.

[0182] Turn the supporting screw rod to make the side mold press tightly against the pads on the steel frame, remove the supporting materials, and lower the inner mold as a whole. The lower section will land on the top support beam of the inner mold (the lower end is a socket or socket) or the limit mark of the prefabricated bottom mold (the lower end is a flat end), and adjust the overall verticality of the inner mold.

[0183] Removal of the inner mold: First, remove the upper plug or socket template in time, loosen the supporting screw of the inner mold, separate the four side panels from the concrete surface, put them in a retracted state, and lift out the inner mold as a whole.

[0184] 2. Segmented prefabrication

[0185] Similar to the segmented overall prefabrication, a movable base mold is configured as needed. The upper and lower sections of the same segment are prefabricated on the same movable base mold, and the same template is used at the tongue and groove position for prefabrication during matching.

[0186] The segment end settings within the same prefabricated unit are the same as described above, the side formwork, steel frame, and inner formwork installation methods are the same, and the side formwork, end formwork removal and inner formwork removal methods are the same.

[0187] The aforementioned "partitioning and centralization" approach can also be adopted to separate the upper and lower sections and centrally prefabricate them.

[0188] 3. The setting of segment hanging points is the same as mentioned above.

[0189] The preferred embodiments for implementing the present invention have been described in detail above, but it should be understood that the role of these embodiments is only to exemplify, and is not intended to limit the scope, applicability or configuration of the present invention in any way. The protection scope of the present invention is defined by the attached claims and their equivalents. A person of ordinary skill in the art can make many changes to the above embodiments under the guidance of the present invention, and these changes all fall within the protection scope of the present invention.

Claims

1. A mobile formwork system for assembled culvert passage, characterized in that: include: A cushion beam, wherein a plurality of cushion beams are arranged in parallel side by side; A first sliding vehicle, wherein a bottom mold is disposed on an upper portion of the first sliding vehicle; A second sliding vehicle is provided on both sides of the first sliding vehicle, and the first sliding vehicle and the second sliding vehicle are provided on corresponding cushion beams and can reciprocate along the cushion beams; Side molds are supported and arranged on the second sliding vehicle; Inner and end molds; A transport trolley, which is arranged on the cushion beam and is located outside one of the second sliding vehicles; as well as Lifting equipment; The end molds include a vertical prefabricated spigot mold, a vertical prefabricated socket mold and a vertical prefabricated tongue-and-groove mold; The vertical prefabricated socket template includes an outer mold top support beam, an inner mold top support beam and a socket slot plate, the socket slot plate is in a U-shaped slot shape, and wing plates are arranged on both sides of the socket slot plate, and the two wing plates are mounted on the outer mold top support beam and the inner mold top support beam; The vertical prefabricated socket template includes an outer mold top support beam, an inner mold top support beam, a socket groove plate and a cushion plate, the socket groove plate is in a U-shaped groove shape, and wing plates are arranged on both sides of the socket groove plate, the socket groove plate is buckled on the outer mold top support beam and the inner mold top support beam, and the cushion plate top support is arranged at the lower part of the socket groove plate; The vertical prefabricated tongue-and-groove template comprises an outer mold top support beam, an inner mold top support beam and a tongue-and-groove groove plate, wherein the tongue-and-groove groove plate is in a V-shaped groove shape, and wing plates are arranged on both sides of the tongue-and-groove groove plate, and the wing plates of the tongue-and-groove groove plate are mounted on the outer mold top support beam and the inner mold top support beam; The assembled culvert passage mobile formwork system also includes a loading and unloading formwork pulley, which includes a first loading and unloading formwork pulley and a second loading and unloading formwork pulley. The first loading and unloading formwork pulley is supported by the cushion beam, and the second loading and unloading formwork pulley is supported by a steel frame or a prefabricated concrete segment.

2. The assembled culvert channel movable formwork system according to claim 1 is characterized in that: The first skid trolley and the second skid trolley both include: Multiple support beams, the support beams are arranged corresponding to the cushion beams, and support rollers are arranged at the bottom of the support beams; A connecting rod, which is connected and arranged between the plurality of supporting beams; The sliding driving part drives the support beam to reciprocate on the cushion beam.

3. The assembled culvert movable formwork system according to claim 2 is characterized in that: Side baffles corresponding to the two sides of the cushion beam are arranged on the support beam, and positioning pins are also arranged between the support beam and the cushion beam.

4. The assembled culvert movable formwork system according to claim 2 or 3, characterized in that: A lateral movement unit and a lateral support unit are provided between the side mold and the second sliding vehicle; the lateral movement unit is used to drive the side mold to move laterally on the second sliding vehicle; The side support unit is used to support the side form; The traverse unit comprises: A transverse roller, which is arranged at the inner bottom of the side mold; an adjusting power push rod, which is disposed between the outer side of the side mold and the second sliding vehicle; and A wooden wedge, which is arranged at the outer bottom of the side form; The side support unit is an adjusting screw, and both ends of the adjusting screw are respectively hingedly arranged on the side mold and the second sliding vehicle.

5. The assembled culvert movable formwork system according to claim 1 is characterized in that: The end mold and the side mold are provided with hanging points, and the hanging points include: A mold box, wherein the mold box is in the shape of a triangular groove, and the notch of the mold box is fitted and fixed to the end surface of the corresponding end mold or side mold; A hanging ring is disposed in the mold box; and A notch is provided on the side wall of the mold box, and the lower end of the hanging ring passes through the notch and is connected to the corresponding steel bar skeleton.

6. The assembled culvert movable formwork system according to claim 1 is characterized in that: The first sliding vehicle, the second sliding vehicle and the transport trolley are all driven by a winch, and a basic base is arranged at the lower part of the cushion beam.

7. A method for horizontal prefabrication of assembled culvert passages, characterized in that: The assembled culvert channel movable formwork system described in any one of claims 1 to 6 is used to carry out horizontal prefabrication construction of the culvert channel.

8. A method for vertical prefabrication of assembled culvert passages, characterized in that: The assembled culvert channel movable formwork system described in any one of claims 1 to 6 is used to carry out vertical prefabrication construction of the culvert channel.

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