An open-cut structure outer mold template for hydraulic tunnel and a construction method thereof

Abstract

The application discloses a water conservancy tunnel open excavation structure outer mold template and a construction method, and relates to the technical field of tunnel construction, in particular to an outer mold template and a construction method for a water conservancy tunnel open excavation structure.

Description

A formwork template and construction method for open-cut hydraulic tunnel structures Technical Field

[0001] This invention relates to the field of hydraulic tunnel construction. More specifically, this invention relates to an external formwork template and construction method for open-cut hydraulic tunnel structures. Background Technology

[0002] A hydraulic tunnel is a water passageway excavated within a mountain or underground. Hydraulic tunnels can be used for irrigation, power generation, water supply, drainage, water conveyance, construction diversion, and navigation. Tunnels where the water flow has a free surface within the tunnel are called unpressurized tunnels; those that fill the entire cross-section, subjecting the tunnel walls to a certain water pressure, are called pressurized tunnels. Hydraulic tunnels mainly consist of an intake, tunnel body, and outlet section (water diversion tunnels for power generation have a pressurized water pipe connected to the rear of the tunnel; water conveyance tunnels and navigation tunnels on canals only have the tunnel body section). Gates can be located at the intake, outlet, or suitable positions inside the tunnel. Energy dissipation and scour prevention facilities are installed at the outlet. To prevent rock collapse and seepage, the tunnel body section is often temporarily supported or permanently lined with anchor-sprayed concrete (using anchor bolts and shotcrete) or reinforced concrete. The tunnel cross-section can be circular, archway-shaped, or horseshoe-shaped. Pressurized tunnels mostly use a circular shape. The layout of the intake and outlet, the selection of the tunnel route, and the shape and size of the tunnel cross-section are constrained by factors such as topography, geology, ground stress, key infrastructure layout, operational requirements, and construction conditions, and need to be determined through technical and economic comparison.

[0003] Traditional hydraulic tunnels employ a cut-and-cover structure, eliminating the need for external formwork. However, this approach presents challenges such as a long excavation and support period, limited working space, difficulty in ensuring construction safety in complex geological conditions, and challenges in maintaining the integrity of the external structure. Summary of the Invention

[0004] The purpose of this invention is to provide an external formwork template and construction method for open-cut structures in hydraulic tunnels, which expands the working face from a mined-out working face to an open-cut working face, providing space for the deployment of various large-scale equipment.

[0005] The technical solution adopted by this invention to solve this technical problem is: an external formwork template for an open-cut hydraulic tunnel structure, comprising:

[0006] Several sets of outer mold templates are arranged longitudinally along the central axis. The outer mold templates include symmetrically arranged outer molds A, B, and C. The outer molds A, B, and C, as well as the outer mold templates arranged longitudinally along the central axis, are connected by bolts.

[0007] Each set of outer mold templates is connected to a set of back frames at the top; each set of outer mold templates is symmetrically connected to a pair of vertical supports on both sides.

[0008] Preferably, one pair of outer molds A of each set of outer mold templates is symmetrically arranged on both sides, with the upper end of outer mold A connected to outer mold B, and the other end of outer mold B connected to outer mold C.

[0009] Preferably, the outer mold C, outer mold A and outer mold B have the same structure from the inside out. The outer mold A includes a panel, horizontal ribs and vertical ribs from the inside out. A ring of edge frame plates is fixed around the outer perimeter of the panel. Several horizontal ribs and vertical ribs are fixed at equal intervals on the edge frame plates. The thickness of the edge frame plates is 1.5-2.5 times the thickness of the panel.

[0010] Preferably, the vertical support includes a vertical channel steel, the lower part of which is connected to the lower ends of outer mold A and outer mold B by hook bolts. The upper part of the vertical channel steel is provided with several reinforcing ribs. The upper part of the vertical channel steel is connected to the arc-shaped support by several transverse supports. The arc-shaped support is connected to outer mold B and outer mold C. The curvature of the arc-shaped support is consistent with the curvature of outer mold B and outer mold C.

[0011] Preferably, the back frame comprises two 20 channel steels arranged horizontally, with several connectors connected to its lower end, and the connectors are fixed to the arc-shaped support.

[0012] Preferably, the horizontal ribs are made of 10# channel steel, the longitudinal ribs are made of 10mm steel bars, the panel thickness is 6mm, and the edge frame plate thickness is 12mm.

[0013] The present invention also provides a construction method using the aforementioned external formwork template for open-cut hydraulic tunnel structures, comprising the following steps:

[0014] 1) Inner mold trolley in place

[0015] After the steel reinforcement process is completed, the inner formwork trolley is placed in place, and after calibration, the inner formwork trolley is installed and fixed.

[0016] 2) Assembly of outer mold template

[0017] The panels of the outer mold template are pre-polished and coated with release agent. Then, each group of templates and the back frame are assembled in groups. After the assembly is completed, a crane is used to lift the template into the installation position, and each group of outer mold templates is lifted and connected in sequence.

[0018] 3) Reinforcement of outer mold template

[0019] After the entire set of templates is installed in place, it is reinforced according to the pouring process, including vertical supports, tie bars and hook bolts, and the installation of embedded parts is carried out at the same time.

[0020] 4) Concrete pouring

[0021] After the template is reinforced, the outer template trolley is used as a support system, and the concrete of the pipe section is poured on the surface of the inner template trolley to complete the cycle of use of the inner and outer templates of one segment.

[0022] 5) Remove the template and proceed to the next cycle.

[0023] The present invention has at least the following beneficial effects:

[0024] (1) Shorten the excavation cycle: The excavation and support of the tunnel structure requires control of the construction progress, which is slow. Open excavation in shallower areas can open up new working faces, and the excavation and support speed is much higher than that of the tunnel structure.

[0025] (2) Expanding the working face: The working face is expanded from the underground excavation working face to the open excavation working face, which provides space for the deployment of various large-scale equipment.

[0026] (3) Shorten the construction cycle: Compared with the external formwork trolley, the prefabricated formwork does not require the additional external formwork trolley track. Moreover, two sets of formwork can be used for construction at the same time, saving the time for equalization and shortening the construction cycle.

[0027] (4) Save construction costs: The price of prefabricated steel formwork is much lower than that of external formwork trolley, which can effectively save construction costs.

[0028] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0029] Figure 1 is a schematic diagram of the external formwork template for the open-cut structure of the hydraulic tunnel of the present invention;

[0030] Figure 2 is a side view of the outer formwork template of the open-cut structure of the hydraulic tunnel of the present invention;

[0031] Figure 3 is a schematic diagram of the outer mold A structure of the present invention;

[0032] Figure 4 is a schematic diagram of the installation of the waterproof layer installation mechanism and track according to an embodiment of the present invention.

[0033] Explanation of reference numerals in the attached drawings: 1 Outer mold A, 2 Outer mold B, 3 Outer mold C, 4 Outer mold template, 5 Panel, 6 Horizontal rib, 7 Longitudinal rib, 8 Side frame plate, 9 Vertical channel steel, 10 Hook bolt, 11 Horizontal support, 12 Arc support, 13 Double 20 channel steel, 14 Connector, 15 Track, 16 First electric push rod, 17 Clamping block, 18 Slider, 19 Automatic nail gun, 20 Second electric push rod, 21 Rubber scraper, 22 Bracket, 23 Roller, 24 Waterproof membrane, 25 Pipe section, 26 Limiting frame. Detailed Implementation

[0034] The present invention will now be described in detail and completely with reference to the accompanying drawings. Those skilled in the art will be able to implement the present invention based on these descriptions. Before describing the present invention with reference to the accompanying drawings, it should be particularly noted that the technical solutions and features provided in various parts of the present invention, including the following description, can be combined with each other without conflict.

[0035] Furthermore, the embodiments of the present invention described below are generally only some, not all, of the embodiments of the present invention. Therefore, all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0036] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. The specific implementation process is as follows:

[0037] As shown in Figures 1-4, the present invention provides an external formwork template 4 for an open-cut hydraulic tunnel structure, comprising:

[0038] Several sets of outer mold templates 4 are arranged longitudinally along the central axis. The outer mold templates 4 include symmetrically arranged outer molds A1, B2 and C3. The outer molds A1, B2 and C3 are connected to each other and the outer mold templates 4 arranged longitudinally along the central axis are connected by bolts.

[0039] Each set of outer mold template 4 is connected to a back frame at the top; each set of outer mold template 4 is symmetrically connected to a pair of vertical supports on both sides.

[0040] This technical solution may also include the following technical details to better achieve the technical effect: one pair of outer molds A1 of each set of outer mold templates 4 are symmetrically arranged on both sides, the upper end of outer mold A1 is connected to outer mold B2, and the other end of outer mold B2 is connected to outer mold C3.

[0041] This technical solution may also include the following technical details to better achieve the technical effect: the outer mold C3, outer mold A1 and outer mold B2 have the same structure from the inside to the outside. The outer mold A1 includes a panel 5, horizontal ribs 6 and vertical ribs 7 from the inside to the outside. A ring of edge frame plate 8 is fixed around the outer periphery of the panel 5. Several horizontal ribs 6 and vertical ribs 7 are fixed at equal intervals on the edge frame plate 8. The thickness of the edge frame plate 8 is 1.5-2.5 times the thickness of the panel 5.

[0042] This technical solution may also include the following technical details to better achieve the technical effect: The vertical support includes a vertical channel steel 9, the lower part of which is connected to the lower end of the outer mold A1 and outer mold B2 through D20 hook bolts 10. The upper part of the vertical channel steel 9 is provided with several reinforcing ribs, which are made of 8# channel steel. The upper part of the vertical channel steel 9 is connected to the arc-shaped support 12 through several horizontal supports 11. The arc-shaped support 12 is made of double 16 channel steel. The arc-shaped support 12 is connected to the outer mold B2 and outer mold C3. The arc of the arc-shaped support 12 is consistent with the arc of the outer mold B2 and outer mold C3. The horizontal channel steel is made of single 16 channel steel. The back frame and the vertical channel steel 9 play a role in fixing the shape and supporting the force of the outer template.

[0043] This technical solution may also include the following technical details to better achieve the technical effect: the back frame includes double 20 channel steel 13 arranged horizontally, and its lower end is connected to several connecting parts 14, which can be made of channel steel, and the connecting parts 14 are fixed to the arc-shaped support 12.

[0044] This technical solution may also include the following technical details to better achieve the technical effect: the horizontal rib 6 is made of 10# channel steel, the longitudinal rib 7 is made of 10mm steel bar, the panel 5 is 6mm thick, and the edge frame plate 8 is 12mm thick.

[0045] This technical solution may also include the following technical details to better achieve the technical effect: the lateral support 11 and the connector 14 are both telescopic rods;

[0046] The arc-shaped support 12 includes an arc-shaped support 12B and an arc-shaped support 12C. The arc-shaped support 12B is connected to the outer mold B2, and the arc-shaped support 12C is connected to the outer mold C3.

[0047] It also includes: a track 15, which extends longitudinally, the length of the track 15 being the length of several sets of outer mold templates 4, and the two ends of the track 15 being detachably fixed to the outer mold templates 4 at both ends;

[0048] The waterproof layer installation mechanism includes: a clamping assembly, an automatic nail gun 19, a slider 18, a flattening assembly, and a material feeding assembly. The clamping assembly is detachably fixed to the end of the track 15. The lower section of the clamping assembly is a first electric push rod 16, and the lower end of the first electric push rod 16 is connected to a clamping block 17. The clamping block 17 has an arc, the arc of which is the same as the arc of the corresponding poured concrete pipe section 25. The slider 18 is slidably mounted on the slide rail, and the automatic nail gun 19 is fixed on the slider 18. The automatic nail gun 19 is positioned perpendicular to the concrete pipe section 25 directly below it. 5. The flattening assembly is fixed on the slider 18. The automatic nail gun 19 is positioned between the flattening assembly and the clamping assembly. The flattening assembly includes a second electric push rod 20 and a rubber scraper 21. The second electric push rod 20 is fixed on the slider 18. The distance between the rubber scraper 21 and the concrete pipe section 25 directly below it is adjusted by the second electric push rod 20. The material feeding assembly is positioned on the other side of the flattening assembly. The material feeding assembly includes a bracket 22 and a roller 23. The waterproof membrane 24 is positioned on the roller 23. The roller 23 is rotatably fixed on the bracket 22.

[0049] It also includes a limiting frame 26, which is set between the flattening component and the feeding component. The limiting frame 26 includes two limiting crossbars that are spaced apart vertically. After the waterproof membrane 24 passes through the two limiting crossbars, it passes through the rubber scraper 21 of the flattening component. The two limiting crossbars of the limiting frame 26 are fixed to the slider 18 or the bracket 22 of the feeding component through a connecting frame.

[0050] In the above scheme, the clamping degree of the clamping block 17 is adjusted by the first electric push rod 16, and the clamping block 17 is used to clamp the discharge end of the waterproof membrane 24. The slider 18 moves on the slide rail to allow the waterproof membrane 24 to be laid on the concrete pipe section 25 through the flattening component, and then fixed by the automatic nail gun 19.

[0051] This invention also provides a construction method for the external formwork 4 of an open-cut structure in a hydraulic tunnel, comprising the following steps:

[0052] 1) Inner mold trolley in place

[0053] After the steel reinforcement process is completed, the inner formwork trolley is placed in place, and after calibration, the inner formwork trolley is installed and fixed.

[0054] 2) Assembly of the outer mold template 4

[0055] The panel 5 of the outer mold template 4 is pre-polished and a release agent is applied. Then, each group of templates and the back frame are assembled in groups. After the assembly is completed, a crane is used to lift the template into the installation position, and each group of outer mold templates 4 is lifted and connected in sequence.

[0056] 3) Reinforcement of outer mold template 4

[0057] After the entire set of templates is installed in place, it is reinforced according to the pouring process, including vertical supports, tie bars and hook bolts, and the installation of embedded parts is carried out at the same time.

[0058] 4) Concrete pouring

[0059] After the template reinforcement is completed, the outer template trolley is used as a support system, and 25mm concrete is poured on the surface of the inner template trolley to complete the use cycle of the inner and outer templates for a 12-meter segment.

[0060] 5) Formwork removal, proceed to the next cycle. Remove the external formwork according to the principle of "install first, then remove," and reuse the removed formwork in the next cycle.

[0061] This technical solution may also include the following technical details to better achieve the technical effect: Step 5) specifically includes:

[0062] 5.1 Remove the tie bars of the outer formwork 4 at both ends, disassemble the assembly between the outer formwork 4 at both ends, and simultaneously remove the outer formwork 4 at both ends;

[0063] 5.2 Adjust the distance between the outer mold B2 and the outer mold C3 and the pipe section 25 to the set distance using the transverse support 11 and the connector;

[0064] 5.3 Install rails 15 on outer molds B2 and C3, and install a total of four sets of rails 15. Install the waterproof layer installation mechanism on the rails 15 and lay the waterproof layer on the outside of the pipe section 25. After all the waterproof layers are laid, remove all templates and components and proceed to the next cycle.

[0065] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. A formwork template for an open-cut hydraulic tunnel structure, characterized in that, include: Several sets of outer mold templates are arranged longitudinally along the central axis. The outer mold templates include symmetrically arranged outer molds A, B, and C. Outer molds A, B, and C, as well as the outer mold templates arranged longitudinally along the central axis, are connected by bolts. Each set of outer mold templates has a corresponding back frame connected to its upper part. The back frame includes double 20mm channel steel arranged horizontally, with several connecting pieces connected to its lower end. These connecting pieces are fixed to arc-shaped supports. Each set of outer mold templates has a pair of vertical supports symmetrically connected to both sides. These vertical supports include vertical channel steel, with their lower parts connected to the lower ends of outer molds A and B via hook bolts. Several [unclear text - possibly a continuation of the previous sentence] are provided on the upper part of the vertical channel steel. The system includes reinforcing ribs; the upper part of the vertical channel steel is connected to an arc-shaped support via several transverse supports; the arc-shaped support is connected to outer molds B and C; the arc of the arc-shaped support is consistent with the arc of outer molds B and C; one pair of outer molds A are symmetrically arranged on both sides of each set of outer mold templates, with the upper end of outer mold A connected to outer mold B and the other end of outer mold B connected to outer mold C; it also includes: a track and a waterproof layer installation mechanism; the track extends longitudinally, and its length is equal to the length of several sets of outer mold templates; both ends of the track are detachably fixed to the outer mold templates at both ends; the waterproof layer installation mechanism includes: a clamping component, an automatic nail gun, and a slider. The system includes a flattening assembly and a material feeding assembly. The clamping assembly is detachably fixed to the end of the track. The lower section of the clamping assembly is a first electric push rod, and the lower end of the first electric push rod is connected to a clamping block. The clamping block has an arc, the arc of which is the same as the arc of the corresponding poured concrete pipe section. A slider is slidably mounted on the track, and an automatic nail gun is fixed on the slider. The automatic nail gun is positioned perpendicular to the concrete pipe section directly below it. The flattening assembly is fixed to the slider, and the automatic nail gun is positioned between the flattening assembly and the clamping assembly. The flattening assembly includes a second electric push rod and a rubber scraper. The second electric push rod is fixed to the slider. The distance between the rubber scraper and the concrete pipe section directly below is adjusted by the second electric push rod. The material feeding assembly is located on the other side of the flattening assembly. The material feeding assembly includes a bracket and a roller. The waterproof membrane is placed on the roller, and the roller is rotatably fixed to the bracket. It also includes a limiting frame, which is located between the flattening assembly and the material feeding assembly. The limiting frame includes two limiting crossbars that are spaced vertically. After the waterproof membrane passes through the two limiting crossbars, it passes through the rubber scraper of the flattening assembly. The two limiting crossbars of the limiting frame are fixed to the slider or the bracket of the material feeding assembly through a connecting frame.

2. The external formwork template for open-cut hydraulic tunnel structures as described in claim 1, characterized in that, The outer mold C, outer mold A and outer mold B have the same structure from the inside out. The outer mold A includes a panel, horizontal ribs and vertical ribs from the inside out. A ring of edge frame plates is fixed around the outer perimeter of the panel. Several horizontal ribs and vertical ribs are fixed at equal intervals on the edge frame plates. The thickness of the edge frame plates is 1.5-2.5 times the thickness of the panel.

3. The external formwork template for open-cut hydraulic tunnel structures as described in claim 2, characterized in that, The horizontal reinforcing bars are made of 10# channel steel, the longitudinal reinforcing bars are made of 10mm steel bars, the panel thickness is 6mm, and the edge frame plate thickness is 12mm.

4. A construction method for the external formwork of an open-cut hydraulic tunnel structure as described in any one of claims 1 to 3, comprising the following steps: 1) Inner formwork trolley placement: After the reinforcement work is completed, the inner formwork trolley is placed and aligned before installation and fixing. 2) Outer formwork assembly: The outer formwork panels are pre-polished and coated with release agent. Then, each set of formwork and the back frame are assembled in groups. After assembly, the formwork is lifted into the installation position using a crane. Each set of outer formwork is then lifted and connected sequentially. 3) Outer formwork reinforcement: After the entire set of formwork is installed, it is reinforced according to the pouring process, including vertical supports, tie bars and hook bolts, and the installation of embedded parts. 4) Concrete pouring: After the formwork reinforcement is completed, the outer formwork trolley is used as a support system to pour the pipe section concrete on the surface of the inner formwork trolley, completing a cycle of use for the inner and outer formwork of one segment. 5) Remove the template and proceed to the next cycle.

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