Concrete lining device for upper and lower bend sections of inclined shaft of water diversion tunnel of hydropower station

Abstract

The application discloses a concrete lining device for upper and lower bend sections of a water diversion tunnel inclined shaft of a hydropower station and belongs to the technical field of concrete construction of water conservancy projects. The concrete lining device for upper and lower bend sections of a water diversion tunnel inclined shaft of a hydropower station comprises a curved needle beam, a curved body formwork device is slidably arranged on the outer surface of the curved needle beam, and the two ends of the curved needle beam are connected with a tunnel through a support structure. The application has the advantages of high reliability, factory production, on-site installation in a tunnel, high construction efficiency, fast progress, low cost, greatly reduced labor intensity of workers and improved mechanization level in construction.

Description

Technical Field

[0001] This invention relates to the field of concrete construction technology in water conservancy projects, and in particular to a concrete lining device for the upper and lower curved sections of the inclined shaft of a hydropower station water diversion tunnel. Background Technology

[0002] According to statistics, my country's exploitable hydropower capacity is approximately 660 million kW, with an annual power generation of about 3 trillion kWh. The construction of pumped storage power stations in my country began in the late 1960s, initially on a relatively small scale. By the 1980s, the construction of a number of large-scale pumped storage power stations in eastern regions such as Guangdong, East China, and North China propelled my country's pumped storage development to new heights. As of 2017, my country ranked first in the world in terms of installed pumped storage capacity, with 28.49 million kW in operation and 38.71 million kW under construction. By 2020, the total operating capacity reached 40 million kW; and by 2025, it is projected to reach approximately 90 million kW. The prospects for both conventional hydropower stations and pumped storage power stations are promising.

[0003] In my country's hydropower station construction, diversion-type power stations account for a considerable proportion. Diversion tunnels, as part of the water charging and releasing system of pumped storage power stations, include inclined and vertical shafts. Slipform technology has been well applied to the inclined and vertical sections of inclined shafts and the vertical sections of vertical shafts. However, the rapid concrete lining technology for the upper and lower curved sections of inclined or vertical shafts has not been well resolved, becoming a technical challenge in hydropower station construction.

[0004] The traditional method involves manufacturing curved wooden formwork with nails in a factory, manually erecting the formwork, and pouring concrete. This technique is outdated, labor-intensive, time-consuming, costly, and carries high safety risks. Summary of the Invention

[0005] The purpose of this invention is to solve the problems in the existing technology of concrete lining methods in the construction of the upper and lower curved sections of the inclined and vertical shafts of hydropower station water diversion tunnels, which are outdated, have high labor intensity, long construction period, high cost and high safety risks. The invention proposes a concrete lining device for the upper and lower curved sections of the inclined shafts of hydropower station water diversion tunnels.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] The concrete lining device for the upper and lower curved sections of the inclined shaft of the hydropower station water diversion tunnel includes a curved needle beam. A curved template device is slidably installed on the outer surface of the curved needle beam. The two ends of the curved needle beam are connected to the tunnel through a support structure.

[0008] The curvature of the curved needle beam is consistent with the center radius and curvature of the tunnel; the length of the curved needle beam is more than twice that of the curved template device.

[0009] Preferably, the curved needle beam adopts a square steel truss structure.

[0010] Preferably, one set of the support structure is provided at each end of the curved needle beam; one set of the support structure is provided on the tunnel wall that has been lined with poured concrete, and the other set of the support structure is provided on the excavated tunnel rock wall.

[0011] Preferably, the support structure consists of a plurality of jacks, which are arranged on the four sides of the curved needle beam.

[0012] Preferably, an adjustable lead screw is rotatably connected to the outer surface of the jack, and the other end of the adjustable lead screw is rotatably connected to the outer surface of the curved needle beam.

[0013] Preferably, the curved template device consists of a curved template block and a template trolley. The template trolley slides on the outer surface of the curved needle beam, and the curved template block is connected to the template trolley via a jack.

[0014] Preferably, the curved template block is composed of four pieces spliced ​​together. Under the extension and retraction action of the jack, the curved template block can extend and open the template surface, or shrink and demold.

[0015] Preferably, the inner side of the curved template device is provided with a pouring hole extending to the outer side; the pouring hole is located near the highest point of the curved template device in its installed state.

[0016] Preferably, a first winch is provided at the front end of the curved needle beam in the direction of movement. The first winch is fixedly installed on the excavated tunnel rock wall, and the first winch pulls the curved needle beam through a rope.

[0017] Preferably, a second winch is provided on the front end side of the curved needle beam in the direction of movement, and the second winch pulls the curved template device through a rope.

[0018] Compared with the prior art, the present invention provides a concrete lining device for the upper and lower curved sections of the inclined shaft of a hydropower station water diversion tunnel, which has the following beneficial effects:

[0019] 1. This invention is technically reliable, manufactured in a factory, and installed on-site inside the tunnel. It has high construction efficiency, fast progress, and low cost, greatly reducing the labor intensity of workers and improving the level of mechanization in construction.

[0020] 2. In this invention, the curved template device is fitted onto the curved needle beam. The curved needle beam and the curved template device move with the mechanical traction of the first winch and the second winch, respectively, enabling multiple cycles of short sections. When the radii of the upper and lower curved sections are the same, they can be flipped over to be used interchangeably, further saving construction costs.

[0021] 3. This invention uses steel instead of wood, saving a lot of wooden formwork, and is highly reusable, safe and environmentally friendly; the overall walking and positioning of concrete lining construction has a lower safety risk compared with the construction and dismantling of wooden formwork.

[0022] The parts of this device not described herein are the same as or can be implemented using existing technologies. This invention is reliable, factory-manufactured, and installed on-site inside the tunnel, resulting in high construction efficiency, fast progress, and low cost. It significantly reduces the labor intensity of workers and improves the level of mechanization in construction. The curved formwork device is fitted onto the curved needle beam, and the curved needle beam and the curved formwork device move with the mechanical traction of the first winch and the second winch, respectively, enabling multiple cycles of short-segment use. When the radii of the upper and lower curved sections are the same, they can be flipped over for mutual use, further saving construction costs. Steel replaces wood, saving a large amount of wooden formwork, and it is highly reusable, safe, and environmentally friendly. The overall walking and positioning of the concrete lining construction has a lower safety risk compared to the erection and dismantling of wooden formwork. Attached Figure Description

[0023] Figure 1 This is a schematic diagram illustrating the usage state of the present invention;

[0024] Figure 2 This is a schematic diagram of the usage state of the present invention located at the lower bend.

[0025] Figure 3 for Figure 2 Enlarged structural diagram at point A;

[0026] Figure 4 This is a schematic diagram of the curved needle beam structure;

[0027] Figure 5 This is a partial cross-sectional structural schematic diagram of the curved body template device;

[0028] Figure 6 A partial sectional view of the curved needle beam and curved template device;

[0029] Figure 7 for Figure 4 Schematic diagram of the cross-sectional structure at point BB;

[0030] Figure 8 for Figure 2 A schematic diagram of the cross-sectional structure at the CC section;

[0031] Figure 9 A schematic diagram of the contracted state structure of the curved body template device;

[0032] Figure 10 This is a schematic diagram of the structure of the present invention in use at the upper bend.

[0033] In the diagram: 1. Curved needle beam; 2. Curved template device; 201. Curved template block; 202. Template trolley; 3. Support structure; 4. Jack; 5. Adjustable screw; 6. First winch; 7. Second winch. Detailed Implementation

[0034] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0035] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0036] Please see Figure 1-10 The concrete lining device for the upper and lower curved sections of the inclined shaft of the hydropower station's water diversion tunnel includes a curved needle beam 1. A curved formwork device 2 is slidably mounted on the outer surface of the curved needle beam 1. Both ends of the curved needle beam 1 are connected to the tunnel via support structures 3. The curvature of the curved needle beam 1 is consistent with the center radius and curvature of the tunnel. The support structures 3 at both ends adjust the axis of the curved needle beam 1 to coincide with the axis of the tunnel. The curved formwork device 2 slides along the curved needle beam 1 to complete the formwork support and concrete pouring construction at different positions.

[0037] The length of the curved needle beam 1 is more than twice that of the curved formwork device 2. Preferably, the length of the curved needle beam 1 is set to be between two and three times that of the curved formwork device 2. If the length of the curved needle beam 1 is set too large, it will increase the installation difficulty and the consumption of materials required for manufacturing. By setting the length of the curved needle beam 1 to be more than twice that of the curved formwork device 2, the curved formwork device 2 can move on the curved needle beam 1 after completing the formwork support for one section of concrete pouring to support the next section of concrete pouring; this provides relative movement support between the curved needle beam 1 and the curved formwork device 2.

[0038] The curved needle beam 1 adopts a square steel truss structure; utilizing the characteristics of the steel truss structure, it has sufficient support strength and low weight; at the same time, it is easy to disassemble and assemble. After processing each component in the factory, it can be initially assembled externally; then transported to the tunnel for final assembly; moreover, the processing of each component is simple and highly reusable; compared with traditional construction that requires a large amount of wooden planks, it is economical and environmentally friendly.

[0039] Support structures 3 are installed at both ends of the curved needle beam 1. One set of support structures 3 is installed on the tunnel wall that has been lined with poured concrete; the other set of support structures 3 is installed on the excavated tunnel rock wall, that is, at the front end of the curved needle beam 1 in the direction of movement. By setting up two support structures 3 to provide support, the curved needle beam 1 is supported from both ends, and the middle part of the curved needle beam 1 forms the moving track of the curved template device 2; during the installation of the support structures 3, the position is precisely adjusted so that the axis of the needle beam is consistent with the axis of the tunnel.

[0040] Specifically, the support structure 3 consists of several jacks 4, which are positioned on the four sides (top, bottom, left, and right) of the curved needle beam 1 to provide stable support. Because both the curved needle beam 1 and the tunnel inner wall are arc-shaped structures, pads are needed during the installation of the jacks 4 to ensure stable installation. Preferably, at least two jacks 4 are placed as a group on the underside of the curved needle beam 1, increasing the support points by at least two to achieve better stability.

[0041] Furthermore, an adjustable lead screw 5 is rotatably connected to the outer surface of the jack 4, and the other end of the adjustable lead screw 5 is rotatably connected to the outer surface of the curved needle beam 1; each jack 4 is equipped with at least two adjustable lead screws 5. The adjustable lead screws 5 provide a higher precision adjustment range and further improve the stability of the support. The rotatable connection between the adjustable lead screw 5 and the curved needle beam 1 and the jack 4 can be achieved by fixing connecting plates with openings to the outer surfaces of the jack 4 and the curved needle beam 1 respectively; a rotating shaft is inserted into the connecting plate, and the rotating shaft penetrates the adjustable lead screw 5, rotatably connecting the adjustable lead screw 5 to the connecting plate. Preferably, two connecting plates are symmetrically arranged on both sides of one end of the adjustable lead screw 5 to increase strength and stability.

[0042] The curved template device 2 consists of a curved template block 201 and a template trolley 202. The template trolley 202 slides on the outer surface of the curved needle beam 1, and the curved template block 201 is connected to the template trolley 202 via jacks 4. The template trolley 202 adopts a steel truss structure and is fitted onto the outer surface of the curved needle beam 1. For the sliding type, a slide rail can be set on the outer surface of the curved needle beam 1, and the template trolley 202 is equipped with corresponding moving wheels. Grease is applied to the slide rail for lubrication to reduce friction. The template trolley 202 slides along the curved needle beam 1 as a track. After sliding to the set position, the position of the template trolley 202 is locked.

[0043] The curved template block 201 is composed of four spliced ​​pieces; the curved template block 201 can extend and open the template surface or shrink and demold under the extension and retraction action of the jack 4; in the open state, the curved template block 201 is consistent with the tunnel lining structure surface.

[0044] Specifically, the curvature of the curved template block 201 is designed to match the curvature of the tunnel; and the upper and lower blocks and the left and right blocks are staggered when they extend and retract.

[0045] One method of setting the curved template block 201 is to set the left and right cross-sections of the upper and lower curved template blocks 201 as vertical planes; when opening the template surface, the left and right curved template blocks 201 are extended first, followed by the upper and lower curved template blocks 201; when retracting the template surface, the upper and lower curved template blocks 201 are retracted first, followed by the left and right curved template blocks 201. Similarly, the two cross-sections of the upper and lower curved template blocks 201 can also be set as horizontal planes or other forms to achieve staggered setting during expansion and contraction.

[0046] On the inner side of the curved formwork device 2, there is a pouring hole that extends to the outer side. The pouring hole is set near the highest point of the curved formwork device 2 in the installed state; so that concrete can be delivered from the pouring hole after the curved formwork device 2 is installed in place; the pouring can be completed in one go near the highest point.

[0047] Alternatively, several pouring holes can be set at different elevation positions of the curved template device 2, and pouring can be carried out layer by layer from bottom to top; before pouring the next layer, the pouring holes of that layer are sealed. Setting multiple pouring holes can further improve the density and pouring effect of the pouring.

[0048] A first winch 6 is installed at the front end of the curved needle beam 1 in the direction of movement. The first winch 6 is fixedly installed on the excavated tunnel rock wall. The first winch 6 moves the curved needle beam 1 by pulling it with a rope.

[0049] A second winch 7 is installed on the front side of the curved needle beam 1 in the direction of movement. The second winch 7 moves the curved template device 2 by pulling it with a rope.

[0050] In practical use, after the concrete lining of a section of the tunnel is poured and reaches a certain strength, the jacks 4 between the curved formwork block 201 and the formwork trolley 202 retract to demold. After demolding, the second winch 7 pulls the curved formwork device 2 forward on the curved needle beam 1, moving the curved formwork device 2 from one concrete pouring section to the next. After the second concrete section of the tunnel is poured, the support structures 3 at both ends of the curved needle beam 1 are retracted, keeping the curved formwork device 2 in its extended state. The first winch 6, located at the front end of the tunnel lining, pulls the curved needle beam 1 forward, adjusting it to be consistent with the tunnel axis during the movement. After moving a distance greater than one concrete lining section, the support structures 3 extend and are fixed to the tunnel. Then, the curved formwork device 2 is moved again. This cycle repeats to complete the concrete lining of the entire curved section.

[0051] Please see Figure 1 The left and right images respectively show the usage diagrams of the lower and upper bends. For the upper and lower bends of the inclined and vertical shafts of the water diversion tunnel, when the diameter and turning radius are the same, the curved needle beam 1 and the curved template device 2 are rotated 180 degrees, and the installation positions of the first winch 6 and the second winch 7 are adjusted accordingly, so that they can be used interchangeably.

[0052] In the specific construction, the curved needle beam 1 and the curved formwork device 2 are designed first according to the shape and size of the tunnel. The upper and lower curved sections of the inclined and vertical shafts of the hydropower station's water diversion tunnel are similar to a part of a fully inflated circular tire with the same radius as the tunnel. The curved needle beam 1 is a curved structure with a smaller center, and the curved formwork device 2 is fitted onto the curved needle beam 1 and is a larger curved structure. After the design is completed, it is processed in the factory and preliminarily assembled according to the dimensions of each part. After being transported to the construction site, it is finally assembled. Before installing the curved needle beam 1, the steel reinforcement binding of the tunnel's curved section is carried out first. After the steel reinforcement binding is completed, the operators fix and install the first winch 6 in the tunnel; it pulls the curved needle beam 1 being installed, providing forward and upward tension. After the curved needle beam 1 is assembled, the support structure 3 at the front end in the direction of movement is installed on the excavated tunnel rock wall, and the support structure 3 at the rear end is installed on the tunnel wall with the poured concrete lining, and adjusted so that the curved needle beam 1 is aligned with the tunnel axis. Next, the curved template device 2 is installed on the curved needle beam 1, and its position is adjusted using the second winch 7. Once the position is determined, the curved template device 2 is extended for support; thick wooden boards are used to reinforce both ends of the template with a top-mounted seal to prevent concrete overflow during pouring. Then, concrete is poured through the designated pouring holes to complete the pouring process; the pouring sequence is bottom-first, then middle-first, and finally top-first. During pouring, a concrete pouring nozzle can be installed at the pouring port to facilitate pumping concrete into the formwork; a manual shut-off valve is installed at the end of the nozzle located inside the template to allow for timely closure of the nozzle when removing the pump pipe after pouring, preventing the freshly poured concrete from flowing out.

[0053] This invention proposes a curved needle beam 1 and a curved formwork device 2 for the concrete lining of the upper and lower curved sections of the inclined and vertical shafts of a circular water diversion tunnel in a hydropower station, as well as a concrete lining construction method using the device. This invention successfully solves a problem that has plagued hydropower construction technology for many years. The device and construction method are technically reliable, manufactured in factories, and installed on-site inside the tunnel. They are fast, low-cost, greatly reduce the labor intensity of workers, and have low safety risks. They also improve the level of mechanization in construction.

[0054] This invention employs a square steel truss curved needle beam 1, whose axial radius matches the upper and lower curved sections of the inclined and vertical shafts of the circular water diversion tunnel, enabling positional movement during construction. The curved formwork device 2 is designed and manufactured as a spatial curved structure, i.e., a partially circular ring with the same radius, whose radius and curvature match the upper and lower curved sections of the inclined and vertical shafts, similar to a portion of a fully inflated circular tire, matching the inner wall of the tunnel. The curved formwork device 2 is fitted onto the curved needle beam 1, and the curved needle beam 1 and the curved formwork device 2 move under the mechanical traction of the first winch 6 and the second winch 7, respectively, to achieve the support and movement of the lining formwork.

[0055] This invention employs a steel curved needle beam 1 and a curved formwork device 2, replacing wood with steel, thus saving a significant amount of wooden formwork. It also boasts high reusability, safety, and environmental friendliness. Factory manufacturing and on-site installation result in high construction efficiency and rapid progress. The curved needle beam 1, combined with the curved formwork device 2, enables multiple cycles of short segments. When the radii of the upper and lower curved sections are consistent, they can be interchanged, further reducing construction costs. The overall walking and positioning of the concrete lining construction poses a lower safety risk compared to the erection and dismantling of wooden formwork.

[0056] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A concrete lining device for the upper and lower curved sections of the inclined shaft of a hydropower station's water diversion tunnel, characterized in that, It includes a curved needle beam (1), on the outer surface of which a curved template device (2) is slidably provided, and the two ends of the curved needle beam (1) are connected to the tunnel through a support structure (3); The curvature of the curved needle beam (1) is consistent with the curvature of the tunnel; the support structures (3) at both ends adjust the axis of the curved needle beam (1) to coincide with the axis of the tunnel; the curved template device (2) slides along the curved needle beam (1) to complete the template support and concrete pouring construction at different positions. The length of the curved needle beam (1) is between two and three times that of the curved formwork device (2); after completing the formwork support of a section of the concrete pouring, the curved formwork device (2) moves on the curved needle beam (1) to the next concrete pouring section for formwork support. The support structure (3) consists of several jacks (4), which are arranged on the four sides of the curved needle beam (1). An adjustable screw (5) is rotatably connected to the outer surface of the jack (4), and the other end of the adjustable screw (5) is rotatably connected to the outer surface of the curved needle beam (1). Each jack (4) is equipped with at least two adjustable screws (5). At least two jacks (4) are arranged as a group on the lower side of the curved needle beam (1) to provide no less than two support points. The curved template device (2) consists of a curved template block (201) and a template trolley (202). The template trolley (202) slides on the outer surface of the curved needle beam (1). The curved template block (201) is connected to the template trolley (202) through a jack (4). The curved template block (201) is composed of four spliced ​​pieces. The curved template block (201) extends and opens the template surface or shrinks and demolds under the extension and retraction action of the jack (4). The curvature of the curved template block (201) is consistent with the curvature of the tunnel. Moreover, the upper and lower pieces and the left and right pieces are staggered when they extend and retract. The curved template block (201) is set as follows: the left and right sections of the upper and lower curved template blocks (201) are set as vertical surfaces; when opening the template surface, the left and right curved template blocks (201) are extended first, and then the upper and lower curved template blocks (201) are extended; when shrinking the template surface, the upper and lower curved template blocks (201) are retracted first, and then the left and right curved template blocks (201) are retracted; or, the two sections of the upper and lower curved template blocks (201) are in the form of horizontal surfaces; The inner side of the curved template device (2) is provided with a pouring hole that extends to the outer side; the pouring hole is set near the highest point of the curved template device (2) in the installed state; or, several pouring holes are set at different elevation positions of the curved template device (2), and pouring is carried out layer by layer from bottom to top. Before moving on to the next layer after completing the first layer of pouring, seal the pouring holes for that layer. During operation: After the position is determined, extend the curved template device (2) for support; and use thick wooden boards to reinforce the two ends of the template by pulling and sealing; then, pour concrete through the set pouring hole to complete the pouring; among them, the pouring procedure is to pour the bottom first, then the middle, and then the top; in addition, install a concrete pouring jet pipe at the pouring port, and set a manual closing gate valve at the end of the jet pipe located inside the template; The curved needle beam (1) adopts a square steel truss structure; after processing each component in the factory, it is initially assembled on the outside; it is transported to the tunnel and then finally assembled; the support structure (3) is set at each end of the curved needle beam (1); one set of the support structure (3) is set on the tunnel wall that has been lined with concrete, and the other set of the support structure (3) is set on the excavated tunnel rock wall; the curved needle beam (1) is supported from both ends, and the middle part of the curved needle beam (1) forms the moving track of the curved template device (2); a first winch (6) is set at the front end of the curved needle beam (1) in the moving direction, and the first winch (6) is fixedly set on the excavated tunnel rock wall, and the first winch (6) pulls the curved needle beam (1) through a rope; a second winch (7) is set on the front end side of the curved needle beam (1) in the moving direction, and the second winch (7) pulls the curved template device (2) through a rope. During use, after a section of the tunnel concrete lining is poured and reaches a certain strength, the jacks (4) between the curved formwork block (201) and the formwork trolley (202) retract to demold. After demolding, the second winch (7) pulls the curved formwork device (2) forward on the curved needle beam (1) to move the curved formwork device (2) from one concrete pouring section to the next. After the second concrete section of the tunnel is poured, the support structures (3) at both ends of the curved needle beam (1) are retracted to keep the curved formwork device (2) in the unfolded state. The first winch (6) set at the front end of the tunnel lining is used to pull the curved needle beam (1) forward and adjust it to be consistent with the tunnel axis during the movement. After moving a distance greater than one concrete lining section, the support structure (3) is extended and fixed to the tunnel. Then, the curved formwork device (2) is moved again. The cycle repeats to complete the concrete lining of the entire curved section.

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