A stainless steel and wood combined formwork applied to fair-faced concrete and its manufacturing method

Abstract

The present invention relates to the field of fair-faced concrete formwork, and particularly to a stainless steel-wood combined formwork applied to fair-faced concrete and a manufacturing method thereof. The formwork includes a support module matching the bottom radian of an inverted "T" capping beam, a drainage gutter steel arranged at the center position of the top of the support module, a plurality of transverse ribs arranged in a comb-like intersection on the top of the support module, a lower formwork module arranged on the transverse ribs, and an upper formwork module arranged above the lower formwork module. The support module includes a plurality of long beams arranged on a capping beam auxiliary support through a leveling unit, and a plurality of main keel trusses, and the main keel trusses are connected into a whole through a connecting unit. By using a template system composed of a PVC environmental protection material laminated with a stainless steel plate, the overall structure of the present invention is lighter, and the same effect as that of a stainless steel formwork can be achieved. Moreover, when the bottom formwork of the present invention is removed, it is not easy to damage the surface of the formed fair-faced concrete, ensuring the appearance quality of the fair-faced concrete.

Description

Technical Field

[0001] The present invention relates to the field of fair - faced concrete formwork, and particularly to a stainless - steel and wood combined formwork applied to fair - faced concrete and a manufacturing method thereof. Background Art

[0002] With the large - scale construction of urban viaducts, the inverted "T" capping beam, as a new structural form of viaducts, is widely adopted. The inverted "T" capping beam is usually fabricated in the form of erecting formwork on supports or brackets, tying the steel bar framework on - site, hoisting the steel bar framework, and casting concrete in - situ. During the fabrication process, stainless - steel formwork is required for shaping. Currently, for fair - faced concrete formwork of special - shaped structures such as inverted "T" capping beams, fixed - type stainless - steel formwork is usually used, and this formwork has the following deficiencies during use:

[0003] 1. The formwork is heavy, imposing a large load on the supports;

[0004] 2. The manufacturing cost is high, which is not conducive to energy conservation and environmental protection;

[0005] 3. Knocks and damages cannot be repaired;

[0006] 4. Demolishing the bottom formwork is likely to damage the surface of the already - formed fair - faced concrete;

[0007] 5. The processing cycle is long, the turnover efficiency is low, it is not easy to be reused, and it is not conducive to the control of the construction progress.

[0008] Therefore, the present invention discloses a new stainless - steel and wood combined formwork for fair - faced concrete and a manufacturing method thereof to solve the above - mentioned technical problems. Summary of the Invention

[0009] To solve the deficiencies existing in the prior art, the present invention provides a stainless - steel and wood combined formwork applied to fair - faced concrete and a manufacturing method thereof.

[0010] The technical solution of the present invention is as follows:

[0011] The present invention provides a stainless - steel and wood combined formwork applied to fair - faced concrete, including a support module matching the bottom curvature of the inverted "T" capping beam, a drain gutter steel arranged at the center position on the top of the support module, a plurality of transverse ribs arranged in a comb - tooth cross - pattern on the top of the support module, a lower formwork module arranged on the transverse ribs, and an upper formwork module arranged above the lower formwork module. The support module includes a plurality of long beams arranged on the capping beam auxiliary support through a leveling unit, and a plurality of main keel trusses uniformly arranged on the long beams. The main keel trusses are connected into a whole through a connecting unit.

[0012] Further, the leveling unit is a U - shaped top support.

[0013] Further, the main keel truss includes a bottom square pipe, an arc - shaped pipe, and a plurality of support pipes with different lengths.

[0014] Furthermore, the connecting unit includes a number of limiting tubes, a number of fixing tubes, and a number of reinforcing steel bars.

[0015] Furthermore, the lower die module includes a number of bottom dies, a number of lower side dies, a pair of lower plugging plates, a number of support structures, and a number of diagonal tension bolts.

[0016] Furthermore, the support structure includes lower support columns and reinforcing gusset plates.

[0017] Furthermore, the upper die module includes a number of upper side dies, a pair of upper plugging plates, a number of upper support columns, a number of tie bolts, and a number of diagonal tension bolts.

[0018] Furthermore, the layered structures of the bottom die, the lower side die, the lower plugging plate, the upper side die, and the upper plugging plate are all wood-plastic boards and thin steel plates.

[0019] A manufacturing method of a stainless steel-wood combined formwork applied to fair-faced concrete includes the following steps:

[0020] S1. Laying long beams: After the erection of the cap beam auxiliary support is completed, first fix the U-shaped top brackets on the top of the cap beam auxiliary support and preliminarily level them, then hoist the long beams onto the U-shaped top brackets, and finally fix the long beams.

[0021] S2. Hoisting the main keel trusses: Hoist the main keel trusses onto the long beams in a certain order, and at the same time fix the fixing tubes on the limiting tubes to achieve preliminary connection between adjacent main keel trusses.

[0022] S3. Strengthening the connection of the main keel trusses: Weld a number of reinforcing steel bars on the bottom square tubes to strengthen the connection between adjacent main keel trusses.

[0023] S4. Laying cross ribs: Arrange the cross ribs in a comb-like and crosswise manner on the top of the support module, and fix the cross ribs into a whole.

[0024] S5. Laying the bottom die: Hoist the bottom die onto the cross ribs in sequence.

[0025] S6. Precise adjustment: The staff adjusts the height of the U-shaped top brackets to make the bottom die coincide with the designed curve at the bottom of the cap beam, and the errors in the horizontal and height directions are within the specified range, and preliminarily fix the bottom die, and then use glue to seal the gaps.

[0026] S6. Installation of the lower plugging plates: First, fix the cap beam steel bar framework on the bottom die, then hoist the plugging plates onto the bottom die and fix them, and at the same time use diagonal tension bolts to fix the plugging plates on the cap beam steel bar framework, and finally use glue to seal the gaps.

[0027] S7. Installation of the lower side formwork. First, fix the support structure and the lower support columns on the main keel truss, then hoist the lower side formwork in sequence and fix it on the lower support columns. After that, use the stay bolts to strengthen the structure, and finally use glue to seal the gaps.

[0028] S8. Installation of the upper side formwork. Hoist the upper support columns and the upper side formwork onto the cover beam steel bar framework, adjust the installation position and fix it with the tie bolts. After that, use glue to seal the gaps.

[0029] S9. Installation of the upper plug plate. Hoist the upper support columns and the upper plug plate onto the cover beam steel bar framework, adjust the installation position and fix it with the stay bolts. After that, use glue to seal the gaps.

[0030] The beneficial effects achieved by the present invention are as follows:

[0031] By using a formwork system composed of a PVC environmental protection material laminated with a stainless steel plate, the overall structure of the present invention is lighter, and the same effect as that of a fixed stainless steel formwork can be achieved. Moreover, when removing the bottom formwork of the present invention, it is not easy to damage the surface of the formed fair-faced concrete, ensuring the appearance quality of the fair-faced concrete.

[0032] At the same time, the present invention does not use all-steel materials like traditional fixed stainless steel formworks, but uses a combination of PVC wood-plastic boards and stainless steel plates, which makes the processing cycle of the present invention short, the turnover efficiency high, and it is easy to reuse, facilitating progress control and greatly reducing the production cost. Moreover, the present invention is provided with a support structure, which is sufficient to ensure that the present invention has the same strength, stiffness, and stability as traditional fixed stainless steel formworks.

[0033] In addition, if a certain formwork or other structure is damaged such as being knocked during the use of the present invention, only the damaged part needs to be repaired or replaced, saving the daily maintenance cost. Description of the Drawings

[0034] Figure 1 It is a partial schematic view of the support module of the present invention.

[0035] Figure 2 It is the front view of the main keel truss of the present invention.

[0036] Figure 3 It is the schematic cross-sectional view of the present invention.

[0037] Figure 4 It is Figure 3 The A-A cross-sectional view in

[0038] Figure 5 It is Figure 4 The partial enlarged view at B in

[0039] Figure 6 It is the layout diagram of the transverse ribs.

[0040] Figure 7 It is a three-dimensional view of the bent cap.

[0041] Figure 8 It is the front view of the bent cap.

[0042] In the figure, 100 is the long beam; 101 is the U-shaped top support; 110 is the main keel truss; 111 is the bottom square pipe; 112 is the arc pipe; 113 is the support pipe; 120 is the limit pipe; 121 is the fixed pipe; 122 is the reinforcing bar; 200 is the drain steel; 300 is the transverse rib; 400 is the bottom formwork; 401 is the wood-plastic board; 402 is the thin steel plate; 410 is the lower side formwork; 420 is the lower plug plate; 430 is the lower support column; 440 is the reinforcing gusset plate; 450 is the diagonal tension bolt; 451 is the backing plate; 500 is the upper side formwork; 510 is the upper plug plate; 520 is the upper support column; 530 is the tie bolt; 600 is the bent cap; 610 is the auxiliary support of the bent cap; 620 is the reinforcing bar framework of the bent cap. Specific embodiments

[0043] To facilitate those skilled in the art to understand the present invention, the specific embodiments of the present invention will be described below with reference to the accompanying drawings.

[0044] As Figures 1 to 8 shown, the present invention provides a stainless steel-wood combined formwork applied to fair-faced concrete, including a support module matching the bottom radian of the inverted "T" bent cap 600, a drain steel 200 arranged at the central position on the top of the support module, a plurality of transverse ribs 300 (made of 80mm×80mm wooden square) arranged in a comb-like cross on the top of the support module, a lower formwork module arranged on the transverse ribs 300, and an upper formwork module arranged above the lower formwork module.

[0045] The support module includes several long beams 100 (made of 150mm*200mm wooden squares) arranged on the capping beam auxiliary support 610 through leveling units, and several main keel trusses 110 evenly arranged on the long beams 100. The main keel trusses 110 are connected into a whole through connecting units. The connecting units include several limiting tubes 120 (made of 48mm*3.2mm steel pipes), several fixing tubes 121 (made of 48mm*3.2mm steel pipes), and several reinforcing bars (made of 12# steel bars). The main keel trusses 110 are arranged at intervals of 900mm along the length direction of the long beams 100. The height and radian of different main keel trusses 110 are determined according to the corresponding positions at the bottom of the inverted "T" capping beam 600, and the main keel trusses 110 are numbered according to the installation positions. Limiting tubes 120 are symmetrically arranged on the left and right sides of the main keel trusses 110, and several fixing tubes 121 are fixed on the limiting tubes 120 through buckles. The function of the fixing tubes 121 is to connect adjacent main keel trusses 110 so that the main keel trusses 110 on the long beams 100 form a whole. Preferably, there are two upper and lower fixing tubes 121 arranged on the limiting tubes 120.

[0046] Among them, the main keel truss 110 includes a bottom square tube 111, an arc tube 112, and several support tubes 113 with different lengths. The arc tube 112 is arranged on the bottom square tube 111 through the support tubes 113. The materials of the bottom square tube 111, the arc tube 112, and the support tubes 113 are all square steel pipes of 60mm*60mm*4mm.

[0047] The capping beam auxiliary support 610 is an auxiliary support assembled with materials such as steel pipes and bolts, and its function is to provide support for the present invention to prevent the present invention from being damaged due to the excessive weight of the cement when pouring the inverted "T" capping beam 600. Due to the uneven ground and construction accuracy, the tops of the capping beam auxiliary supports 610 are surely not on the same horizontal plane after being erected. Therefore, in order to ensure the subsequent construction accuracy, the leveling unit needs to be used for leveling. The leveling unit is a U-shaped jack 101, and its bottom end is fixed on the top of the capping beam auxiliary support 610.

[0048] The lower die module includes several bottom dies 400, several lower side dies 410, a pair of lower plugging plates 420, several support structures, and several diagonal bolts 450. The bottom dies 400, lower side dies 410, and lower plugging plates 420 are all prefabricated on the ground according to the shape of the inverted "T" capping beam 600 and other construction requirements, and numbered in sequence to facilitate subsequent hoisting. The support structure includes lower support columns 430 (made of 60mm * 60mm * 4mm square steel pipes) and strengthening gusset plates 440. The lower support columns 430 are welded to the arc-shaped pipe 112, and the strengthening gusset plates 440 are welded between the lower support columns 430 and the arc-shaped pipe 112 for structural strengthening. The lower support columns 430 are used for strengthening the structure of the lower side die 410 to prevent the lower side die 410 from deforming, and the strengthening gusset plates 440 are used to fix the lower support columns 430 to prevent the pressure of the cement from pushing the lower side die 410 away during the pouring of the capping beam 600, resulting in the outflow of the cement. One end of the diagonal bolt 450 passes through the backing plate 451, the lower support column 430, the lower side die 410 and is fixedly connected to the capping beam steel bar framework 620, and the other end is screwed with a nut and gradually tightened to adjust and fix the installation position of the lower side die 410 to prevent the lower side die 410 from moving under the pressure of the cement, resulting in the deformation of the capping beam 600. The lower edge of the lower plugging plate 420 is provided with a hem, and several screw holes are provided on the hem. The lower plugging plate 420 is connected to the bottom die 400 and the transverse rib 300 as a whole by screws, and the bottom die 400 extends out of the lower plugging plate 420. The lower plugging plate 420 is fixed to the capping beam steel bar framework 620 by several diagonal bolts 450 to prevent the deformation of the capping beam 600 during pouring.

[0049] Furthermore, the upper die module includes several upper side dies 500, a pair of upper plugging plates 510, several upper support columns 520 (made of 60mm * 60mm * 4mm square steel pipes), several tie bolts 530, and several diagonal bolts 450. The upper side dies 500 and upper plugging plates 510 are all prefabricated on the ground according to the shape of the inverted "T" capping beam 600 and other construction requirements, and numbered in sequence to facilitate subsequent hoisting. First, hoist the upper side dies 500 and upper support columns 520, hoist the two opposite left and right upper side dies 500 together onto the capping beam steel bar framework 620, and then adjust and fix the upper side dies 500 through the upper, middle and lower tie bolts 530 so that the lower edge of the upper side die 500 is at the same horizontal plane as the upper edge of the lower side die 410.

[0050] Specifically, the fixing method of the tie bolt 530 is as follows: one end of the tie bolt 530 passes through the backing plate 451, the upper support column 520, the upper side form 500, the cap beam steel bar framework 620, another opposite upper side form 500, the opposite upper support column 520, and the backing plate 451 in sequence, and then nuts are tightened at both ends of the tie bolt 530 to fix the upper side form 500 on the cap beam steel bar framework 620, and the tie bolt 530 is tied firmly to the cap beam steel bar framework 620 with iron wire. Among them, the function of the upper support column 520 is to strengthen the structure of the upper side form 500 and prevent the upper side form 500 from deforming concavely and convexly under the action of the cement pressure. After that, the upper plug plate 510 and the upper support column 520 are hoisted, and the upper plug plate 510 is fixed on the cap beam steel bar framework 620 with several diagonal tie bolts 450.

[0051] Among them, the laminated structures of the bottom form 400, the lower side form 410, the lower plug plate 420, the upper side form 500, and the upper plug plate 510 are all wood-plastic boards 401 and thin steel plates 402. The material of the wood-plastic board 401 is a 15-mm-thick PVC wood-plastic board 401, the material of the thin steel plate 402 is a 1-mm-thick 304 stainless steel plate, and the thin steel plate 402 is pasted on the wood-plastic board 401 with an epoxy resin binder to achieve a perfect fit and meet the specification requirements. After that, the thin steel plate 402 is polished and coated with formwork paint to prevent damage to the surface of fair-faced concrete during subsequent demoulding and affect the appearance effect of fair-faced concrete. The model of the formwork paint is EP-2 demoulding agent for small precast components.

[0052] A manufacturing method of a stainless steel-wood combined formwork applied to fair-faced concrete includes the following steps:

[0053] S1. Laying the long beam 100. After the cap beam auxiliary support 610 is set up, first fix the U-shaped top support 101 on the top of the cap beam auxiliary support 610 and preliminarily level it so that the upper surfaces of the U-shaped top supports 101 are on the same horizontal plane, then hoist the long beam 100 onto the U-shaped top support 101, and finally fix the long beam 100; the fixing method is as follows: first, tie and fix the long beam 100 and the U-shaped top support 101 by tying steel bars, and then establish a reliable connection between the two ends of adjacent long beams 100 through splints and nails so that the long beams 100 are integrated.

[0054] S2. Hoisting the main keel truss 110. Hoist the main keel truss 110 onto the long beam 100 in a certain order, and at the same time fix the fixing pipe 121 on the limiting pipe 120 to achieve preliminary connection between adjacent main keel trusses 110;

[0055] S3. Strengthening the connection of the main keel truss 110. Weld several reinforcing bars 122 on the bottom square pipe 111 to strengthen the connection between adjacent main keel trusses 110;

[0056] S4. Lay the transverse ribs 300, hoist the transverse ribs 300 to the top of the support module at an interval of 100 mm each, ensure that the transverse ribs 300 are parallel to the drainage ditch steel 200, and arrange them in a comb-like and crosswise manner; after the arrangement is completed, carry out reinforcement to make all the transverse ribs 300 an integral whole;

[0057] S5. Lay the bottom formwork 400, hoist the bottom formwork 400 onto the transverse ribs 300 in sequence;

[0058] S6. Precision adjustment, the staff adjusts the height of the U-shaped top support 101 to make the bottom formwork 400 fit the designed curve at the bottom of the capping beam 600, and the errors in both the horizontal and height directions are within the specified range. Then, preliminarily fix the bottom formwork 400, and afterwards, use glue to seal the gaps to make it airtight and leakage-free. The glue includes sealant, double-sided tape, and foaming glue;

[0059] S6. Installation of the lower plug plate 420. First, hoist the capping beam steel bar framework 620 tied on the ground onto the bottom formwork 400 or directly tie the capping beam steel bar framework 620 on the bottom formwork 400. Then, hoist the plug plate onto the bottom formwork 400 and fix it. At the same time, use the diagonal bracing bolts 450 to fix the plug plate on the capping beam steel bar framework 620. Finally, use glue to seal the gaps;

[0060] S7. Installation of the lower side formwork 410. First, fix the support structure and the lower support columns 430 on the main keel truss 110. Then, hoist the lower side formwork 410 in sequence and fix it on the lower support columns 430. After that, use the diagonal bracing bolts 450 for structural strengthening. Finally, use glue to seal the gaps;

[0061] S8. Installation of the upper side formwork 500. Hoist the upper support columns 520 and the upper side formwork 500 onto the capping beam steel bar framework 620, adjust the installation position and fix it with the tension bolts 530. Then, use glue to seal the gaps;

[0062] S9. Installation of the upper plug plate 510. Hoist the upper support columns 520 and the upper plug plate 510 onto the capping beam steel bar framework 620, adjust the angle and fix it with the diagonal bracing bolts 450. Then, use glue to seal the gaps.

[0063] After the erection of the present invention is completed, the subsequent pouring work can be carried out. First, pour the lower half of the inverted "T" capping beam 600 (i.e., the three-dimensional space enclosed by the bottom formwork 400, the lower side formwork 410, and the lower plug plate 420). After waiting for 1 hour for the bottom of the capping beam 600 to initially set and have a certain strength, pour the upper half of the capping beam 600 (i.e., the three-dimensional space enclosed by the upper side formwork 500, the upper surface of the bottom of the capping beam 600, and the upper plug plate 510). After the capping beam 600 is completely set, the formwork can be disassembled.

[0064] The embodiments of the present invention described above do not limit the protection scope of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the claims of the present invention.

Claims

1. A stainless steel and wood combined formwork applied to fair-faced concrete, characterized in that: A formwork system is composed of a stainless steel plate laminated with PVC environmental protection material; it includes a support module matching the bottom arc of the inverted "T" capping beam, a drainage gutter steel arranged at the center of the top of the support module, a number of transverse ribs arranged in a comb-like cross on the top of the support module, a lower die module arranged on the transverse ribs, and an upper die module arranged above the lower die module; the support module includes a number of long beams arranged on the capping beam auxiliary support through a leveling unit, and a number of main keel trusses evenly arranged on the long beams, and the main keel trusses are connected into a whole through a connecting unit; the lower die module includes a number of bottom dies, a number of lower side dies, a pair of lower plugging plates, a number of support structures, and a number of inclined stay bolts, the support structure includes a lower support column and a strengthening gusset plate, the lower support column is welded on the arc-shaped pipe, and the strengthening gusset plate is welded between the lower support column and the arc-shaped pipe; the lower plugging plate is integrated with the bottom die and the transverse rib by screws, and the bottom die extends out of the lower plugging plate; the lower plugging plate is fixed on the capping beam steel bar framework through a number of inclined stay bolts; one end of the inclined stay bolt passes through the backing plate, the lower support column, the lower side die and is fixedly connected with the capping beam steel bar framework, and the other end is screwed with a nut and gradually tightened to adjust and fix the installation position of the lower side die; the upper die module includes a number of upper side dies, a pair of upper plugging plates, a number of upper support columns, a number of tie bolts, and a number of inclined stay bolts, one end of the tie bolt sequentially passes through the backing plate, the upper support column, the upper side die, the capping beam steel bar framework, another opposite upper side die, the opposite upper support column, and the backing plate, and then nuts are tightened at both ends of the tie bolt to fix the upper side die on the capping beam steel bar framework, and the tie bolt is tied to the capping beam steel bar framework with iron wire; the layered structures of the bottom die, the lower side die, the lower plugging plate, the upper side die, and the upper plugging plate are all wood-plastic boards and thin steel plates; the thin steel plate is pasted on the wood-plastic board through an epoxy resin binder.

2. The stainless steel-wood combined formwork applied to fair-faced concrete according to claim 1 is characterized in that: The leveling unit is a U-shaped jack.

3. The stainless steel-wood combined formwork applied to fair-faced concrete according to claim 2, wherein: The main keel truss includes a bottom square pipe, an arc-shaped pipe, and a number of support pipes with different lengths; the arc-shaped pipe is arranged on the bottom square pipe through the support pipes.

4. The stainless steel and wood combined formwork applied to fair-faced concrete according to claim 3, wherein: The connecting unit includes a number of limit pipes, a number of fixed pipes, and a number of strengthening steel bars; a number of fixed pipes are fixed on the limit pipes through buckles; a number of strengthening steel bars are welded on the bottom square pipe to strengthen the connection between adjacent main keel trusses.

5. A stainless steel-wood combined formwork applied to fair-faced concrete according to claim 4, and its manufacturing method includes the following steps: S1. Lay the long beams. After the capping beam auxiliary support is erected, first fix the U-shaped jacks on the top of the capping beam auxiliary support and preliminarily level them, then hoist the long beams onto the U-shaped jacks, and finally fix the long beams. S2. Hoist the main keel trusses. Hoist the main keel trusses onto the long beams in a certain order, and at the same time fix the fixed pipes on the limit pipes to achieve preliminary connection between adjacent main keel trusses. S3. Strengthen the connection of the main keel trusses. Weld a number of strengthening steel bars on the bottom square pipe to strengthen the connection between adjacent main keel trusses. S4. Lay the transverse ribs, arrange the transverse ribs with comb teeth crossed on the top of the support module, and fix the transverse ribs into a whole; S5. Lay the bottom formwork, and hoist the bottom formwork onto the transverse ribs in sequence; S6. Precision adjustment: The staff adjusts the height of the U-shaped top support to make the bottom formwork coincide with the design curve at the bottom of the capping beam. The errors in both the horizontal and height directions are within the specified range, and the bottom formwork is preliminarily fixed. Then, use glue to seal the gaps; S6. Installation of the lower plug plate: First, fix the capping beam steel bar framework on the bottom formwork, then hoist the plug plate onto the bottom formwork and fix it. At the same time, use stay bolts to fix the plug plate on the capping beam steel bar framework. Finally, use glue to seal the gaps; S7. Installation of the lower side formwork: First, fix the support structure and the lower support columns on the main keel truss, then hoist the lower side formwork in sequence and fix it on the lower support columns. Then, use stay bolts for structural strengthening. Finally, use glue to seal the gaps; S8. Installation of the upper side formwork: Hoist the upper support columns and the upper side formwork onto the capping beam steel bar framework, adjust the installation position and fix it with tie bolts. Then, use glue to seal the gaps; S9. Installation of the upper plug plate: Hoist the upper support columns and the upper plug plate onto the capping beam steel bar framework, adjust the installation position and fix it with stay bolts. Then, use glue to seal the gaps.

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