Bridge construction pier body production process

Abstract

The present application belongs to the technical field of bridge engineering, and particularly relates to a bridge construction pier body production process. The present application firstly sets a pipe body fixing frame and a vibrating rod hose scale line, then inserts and connects a concrete pouring hose and a vibrating rod hose, and then matches and lifts the concrete pouring hose and the vibrating rod hose upwards, finally realizes a continuous concrete pouring and vibrating process, ensures that the pier body has less bubbles, good overall structure, greater strength, and relatively smaller appearance color difference. In addition, the present application also provides a pipe body fixing frame used in the above concrete pouring and vibrating process, which has a structure including a bottom plate, a U-shaped steel, a middle circular ring unit, a side edge bottom plate unit, and a supporting rod unit, ensures that the continuous concrete pouring and vibrating process is more stable and convenient, and further ensures that the vibrating rod hose is not easy to be bent and damaged when being lifted.

Description

Technical Field

[0001] This invention belongs to the field of bridge engineering technology, and in particular relates to a bridge pier manufacturing process. Background Technology

[0002] Generally, a bridge pier structure consists of an upper cap and a lower pier body; the former connects to the bridge, and the latter connects to the ground. The pier body is mainly composed of a steel mesh cage and concrete; therefore, the quality of the concrete pouring process directly affects the structural strength of the pier body.

[0003] The existing common pier casting production process mainly includes the following steps: first, pour the bottom layer of concrete for vibration, then vibrate and mix the concrete with a vibrator, then pour a new layer of concrete, and then vibrate again. Repeat the above combination many times to obtain a complete pier product.

[0004] The advantages of this process are that concrete pouring and vibration operations are relatively simple and convenient, with no time restrictions, allowing for thorough vibration and the ability to pause and adjust at any time. However, its disadvantages are more prominent: the overall construction period is relatively long, the allowable air ingress time within the concrete is also longer, and the degree of curing varies significantly between each vibrated layer. Ultimately, this manifests in the pier product as significant color differences, increased air bubbles, and poor overall structural integrity and insufficient strength.

[0005] Therefore, it is now necessary to improve the entire concrete pouring and vibration process. For example, Chinese invention patent with publication number CN108425322A and publication date of August 21, 2018, discloses a method for setting up a vibration channel for pouring concrete in block 0 of a continuous beam: 1. Opening vibration holes; 2. Laying out tremie pipes; 3. Pre-setting the vibration channel; 4. Concrete construction.

[0006] The method described in this invention patent involves uniformly setting vertical and oblique vibration channels to vibrate in all directions without leaving any blind spots, achieving full coverage of concrete vibration at the bottom of the beam and near the supports, thus ensuring concrete quality.

[0007] However, this concrete pouring vibration method only improves the primary and relatively minor degree of vibration by changing the vibration method, and it still cannot significantly improve the overall integrity of the bridge pier's poured structure.

[0008] On the other hand, the concrete pouring and vibration operations lack necessary auxiliary devices to ensure the stability and convenience of the concrete pouring and vibration methods.

[0009] Therefore, in summary, there is an urgent need for a new type of concrete pouring and vibration process based on an auxiliary device for concrete pouring and vibration operation, in order to ensure that the completed bridge piers have greater structural strength. Summary of the Invention

[0010] This invention provides a bridge pier production process that first sets up a pipe fixing frame and a vibrator hose scale line, then inserts the concrete pouring hose and the vibrator hose, and then lifts the concrete pouring hose and the vibrator hose upwards in a matching manner, ultimately achieving a continuous concrete pouring and vibration process. This ensures fewer air bubbles in the pier body, better structural integrity, greater strength, and relatively smaller color difference in appearance.

[0011] In addition, the present invention also provides a pipe fixing frame for the above-mentioned concrete pouring vibration process, the structure of which includes a base plate, a U-shaped steel, a central ring unit, a side base plate unit, and a support rod unit, to ensure that the continuous concrete pouring vibration process is more stable and convenient, and to ensure that the vibrating rod hose is not easily bent or damaged when lifted.

[0012] The technical solution adopted by the present invention to solve the above problems is: a bridge pier manufacturing process, which includes the following steps in sequence:

[0013] S1. Set a pipe fixing frame on the upper edge of the pier formwork, and set a scale line corresponding to the depth of the vibration layer on the outer ring surface of the vibratory rod hose.

[0014] S2. Insert the concrete pouring hose and the vibrating rod hose into the pipe body fixing frame;

[0015] S3. Start the concrete pump truck and vibrator, so that the concrete pouring hose continuously pours concrete and is lifted upward, and the vibrator hose is lifted upward intermittently to ensure that the vibrator body performs concrete vibration operation at the corresponding depth of all vibration layers.

[0016] S4. The concrete pouring hose and the vibrator hose are disconnected from the pipe fixing frame, and the pipe fixing frame is removed from the pier formwork. After the concrete has cured and formed, the pier body is obtained.

[0017] A further preferred technical solution is that, in S2, the number of concrete pouring hoses is 1, and the number of vibrating rod hoses is ≥4.

[0018] A further preferred technical solution is that, in S3, the upward lifting method of the concrete pouring hose is either continuous or intermittent.

[0019] A pipe fixing frame for bridge pier construction production process includes: a base plate set on the upper edge of the pier template; a U-shaped steel set on the upper surface of the base plate; a central ring unit set on the base plate and the U-shaped steel for inserting concrete pouring hose; a side base plate unit set on the U-shaped steel for installing the vibrator host and vibrator hose; and a support rod unit screwed onto the central ring unit for reducing the bending amplitude of the vibrator hose.

[0020] A further preferred technical solution is that: the side plate of the U-shaped steel is provided with mounting holes, the central ring unit includes a ring body, a high-position rod disposed on the outer ring surface of the ring body and inserted into the mounting holes, and a support vertical plate disposed on the outer ring surface of the ring body and pressed against the surface of the base plate.

[0021] A further preferred technical solution is that the side base plate unit includes a main base plate disposed on the two U-shaped steels, and a flexible hose limiting hole plate disposed on the U-shaped steels.

[0022] A further preferred technical solution is that the main unit base plate and the hose limiting hole plate are respectively located on both sides of the tube body fixing frame.

[0023] A further preferred technical solution is that the support rod unit includes an internally threaded ring disposed on the outer ring surface of the main ring body, and a support rod disposed on the outer ring surface of the internally threaded ring and used to lift and fix the vibrating rod hose.

[0024] A further preferred technical solution is that: there are a total of 4 supporting vertical plates, which are set in pairs on 2 of the base plates.

[0025] A further preferred technical solution is that the support rod unit further includes a low-position screw hole plate disposed on the outer ring surface of the internal thread ring, and two supporting vertical plates disposed on the low-position screw hole plate and connected in pairs by snapping together to fix the support rod body. Attached Figure Description

[0026] Figure 1 This is a schematic diagram illustrating an implementation method for continuous concrete pouring and vibration in the production process of this invention.

[0027] Figure 2 This is a schematic diagram of the tube fixing frame in this invention.

[0028] Figure 3 This is a schematic diagram showing the position of the U-shaped steel in this invention.

[0029] Figure 4 This is a schematic diagram of the position and structure of the central annular unit in this invention.

[0030] Figure 5 This is a schematic diagram illustrating the working principle of the support rod unit in this invention.

[0031] Figure 6 This is a schematic diagram of the position and structure of the support rod unit in this invention.

[0032] Figure 7 This is a schematic diagram showing the position and shape of the low-position screw hole plate in this invention.

[0033] The meanings of the markings in the diagram are as follows:

[0034] a) Pier formwork, b) Vibrator hose, c) Concrete pouring hose, d) Vibrator body, e) Vibrator main unit, f) Vibration layer depth, g) Hose lifting position, h) Hose straight placement position.

[0035] 1. Base plate; 2. U-shaped steel; 3. Central ring unit; 4. Side base plate unit; 5. Support rod unit; 6. Mounting hole;

[0036] The components include: circular ring body 301, high position rod 302, support vertical plate 303, main unit base plate 401, hose limiting hole plate 402, internal thread ring 501, support rod body 502, low position screw hole plate 503, and adjusting bolt 504. Detailed Implementation

[0037] The following description is only a preferred embodiment of the present invention and is not intended to limit the scope of the present invention.

[0038] As attached Figure 1-7 As shown, a bridge pier manufacturing process includes the following steps:

[0039] S1. Set a pipe fixing frame on the upper edge of the pier body template a, and set a scale line corresponding to the depth of the vibration layer on the outer ring surface of the vibrating rod hose b.

[0040] S2. Insert the concrete pouring hose c and the vibrating rod hose b into the pipe body fixing frame;

[0041] S3. Start the concrete pump truck and vibrator, so that the concrete pouring hose c continuously pours concrete and is lifted upward, and the vibrator hose b is lifted upward intermittently, so that the vibrator body d performs concrete vibration operation at the corresponding depth of all vibration layers.

[0042] S4. The concrete pouring hose c and the vibrator hose b are disconnected from the pipe fixing frame. The pipe fixing frame is removed from the pier body template a. After the concrete has cured and formed, the pier body is obtained.

[0043] In this embodiment, when the scale line is raised to the position of the pipe fixing frame, i.e., exposed and visible, the vibrator main unit e is turned on for 2-10 minutes to ensure that all the vibrators d can fully and appropriately mix the concrete at each vibration layer depth f, avoiding the generation of a large number of air bubbles inside. At this time, the concrete pouring hose c is constantly performing concrete pouring operations in a relatively slow and appropriate manner. Therefore, the final pier product not only has a small color difference in appearance, but more importantly, it has fewer internal air bubbles, good structural integrity, and high pier support structure strength.

[0044] In addition, the most important aspect of this process is the concrete pouring speed of the concrete pump truck. It needs to be adjusted and matched with at least the following parameters: concrete type, cross-sectional area of ​​the pier, vibration time required, and lifting speed of the concrete pouring hose C, to ensure: 1. Continuous concrete pouring and the shortest possible overall construction period; 2. Each vibrating layer is fully and evenly vibrated.

[0045] Furthermore, in S3, the upward lifting effect of the concrete pouring hose c is achieved by the lifting action of the concrete pump truck itself, while the upward lifting effect of the vibrating rod hose b requires additional upward lifting power, such as an existing crane.

[0046] In S2, the number of concrete pouring hoses c is 1, and the number of vibrating rod hoses b is ≥4.

[0047] In this embodiment, multiple concrete vibrators are distributed as evenly as possible to ensure that the effective vibration area covers the entire cross-section of the bridge pier.

[0048] In S3, the upward lifting method of the concrete pouring hose c is either continuous or intermittent.

[0049] In this embodiment, there are no specific restrictions on the upward lifting method of the concrete pouring hose c, as long as the concrete pouring speed is appropriate. In other words, the concrete pouring operation of the concrete pouring hose c can also be carried out in a variable flow rate manner, ultimately ensuring continuous pouring and a short overall construction period.

[0050] A pipe fixing frame for bridge pier construction production process includes: a base plate 1 set on the upper edge of the pier template a; a U-shaped steel 2 set on the upper surface of the base plate 1; a central ring unit 3 set on the base plate 1 and the U-shaped steel 2 for inserting concrete pouring hose c; a side base plate unit 4 set on the U-shaped steel 2 for installing vibrator host e and vibrator hose b; and a support rod unit 5 screwed onto the central ring unit 3 for reducing the bending amplitude of vibrator hose b.

[0051] In this embodiment, the pipe fixing frame is essentially a steel structure grid. The U-shaped steel 2 is screwed or welded to the base plate 1, and the central ring unit 3 is used to avoid or reduce the left and right swaying of the concrete pouring hose c.

[0052] In addition, the side base plate unit 4 is used to stably install the entire concrete vibrator equipment, which consists of the vibrator main unit e, the vibrator hose b, and the vibrator body d.

[0053] Finally, without the support rod unit 5, the vibrating rod hose b would consist of two roughly perpendicular sections: a horizontal section and a vertical section. In this case, the bending amplitude at the 90° right angle would be relatively large, resulting in significant damage to the tube. However, with the support rod unit 5 installed, the single 90° right angle is replaced by two obtuse angle bends, thus reducing the degree of damage caused by bending. This is one of the functions of the support rod unit 5.

[0054] It should also be noted that when the horizontal section of the vibratory rod hose b is significantly raised, i.e., when the pier body production process is in its later stages, this horizontal section has already separated from the support rod unit 5. At this point, the aforementioned effects of reducing the bending amplitude and protecting the hose from damage have become ineffective. Therefore, the hose protection effect of the support rod unit 5 is only effective during the initial installation and lifting phases of the vibratory rod hose b, with the installation and positioning time being relatively long. This is also a manifestation of the value of the support rod unit 5.

[0055] The side plate of the U-shaped steel 2 is provided with mounting holes 6. The central ring unit 3 includes a ring body 301, a high-position rod 302 disposed on the outer ring surface of the ring body 301 and inserted into the mounting holes 6, and a support vertical plate 303 disposed on the outer ring surface of the ring body 301 and pressed against the upper surface of the base plate 1.

[0056] In this embodiment, the opening of the U-shaped steel 2 faces downward. The advantage of this arrangement is that the specifications of the mounting bolts between the base plate 1 and the U-shaped steel 2 are not limited by the width of the U-shaped steel opening.

[0057] Furthermore, the central annular unit 3 has both the insertion relationship of the high-position rod 302 and the support relationship of the support vertical plate 303, thus directly ensuring that the annular body 301 and indirectly ensuring that the concrete pouring hose c is not easily displaced to the left or right.

[0058] The side base plate unit 4 includes a main unit base plate 401 disposed on the two U-shaped steels 2, and a flexible hose limiting hole plate 402 disposed on the U-shaped steels 2.

[0059] In this embodiment, the upper surface of the main unit base plate 401 is used to screw the vibrating rod main unit e, and the vibrating rod hose b passes through the round hole on the hose limiting hole plate 402 from top to bottom.

[0060] The main unit base plate 401 and the hose limiting hole plate 402 are respectively located on both sides of the pipe body fixing frame.

[0061] In this embodiment, the positioning relationship between the main unit base plate 401 and the hose limiting hole plate 402, which are on opposite sides and far apart from each other, allows the horizontal section of the vibrating rod hose b to be as long as possible.

[0062] Otherwise, the end of the vibratory rod hose b near the main unit mounting end needs to be bent downwards immediately. In this case, the connection structure between the vibratory rod hose b and the vibratory rod main unit e will be subjected to relatively large tensile and deformation forces, making the vibratory rod hose b prone to detachment. Furthermore, this is also the basis for the installation and use of the support rod unit 5.

[0063] The support rod unit 5 includes an internal threaded ring 501 disposed on the outer ring surface of the ring body 301, and a support rod body 502 disposed on the outer ring surface of the internal threaded ring 501 and used to lift and fix the vibrating rod hose b.

[0064] In this embodiment, the support rod 502 divides the original horizontal section of the vibrating rod hose b into two bent sections. At this time, there are no right-angle bends on the entire vibrating rod hose b, and its degree of bending damage will be greatly reduced.

[0065] In addition, the internal threaded ring 501 also provides the support rod 502 with an adjustable vertical height, ensuring that the support rod 502 provides a suitable lifting height for the horizontal section of the vibrating rod hose b.

[0066] Furthermore, during the entire lifting process, the vibratory rod hose b should be bent as much as possible during the lifting action itself, as this would greatly shorten its effective service life.

[0067] There are a total of four supporting vertical plates 303, which are arranged in pairs on the two base plates 1. The supporting rod unit 5 also includes a low-position screw hole plate 503 disposed on the outer ring surface of the internal threaded ring 501, and an adjusting bolt 504 disposed on the low-position screw hole plate 503 and used to fix the supporting rod body 502 by snapping together the two supporting vertical plates 303.

[0068] In this embodiment, the adjusting bolt 504 is engaged between the two paired support vertical plates 303, which ensures that the support rod 502 is not prone to accidental rotation or elevation after the height is adjusted. This is the most crucial aspect.

[0069] However, the above advantages also come at a "cost". The height adjustment of the support rod 502 can no longer be stepless. The smallest unit of its rotation adjustment is 180°. Moreover, the support rod 502 and the horizontal section of the vibrating rod hose b can only be perpendicular to each other. No additional cross angle can be selected. That is, the low-position screw hole plate 503 and the support rod 502 form a 90° angle.

[0070] Finally, the support rod 502 is positioned at a suitable high point, and the horizontal section of the vibrating rod hose b is bent into two ends at an angle of 100-120° to ensure that the effective use time of the support rod 502 is as long as possible.

[0071] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various modifications can be made without departing from the spirit of the present invention. These are non-inventive modifications and are protected by patent law as long as they fall within the scope of the claims of the present invention.

Claims

1. A manufacturing process for bridge pier bodies, characterized in that... The steps are as follows: S1. Set a pipe fixing frame on the upper edge of the pier body template (a) and set a scale line corresponding to the depth of the vibration layer on the outer ring surface of the vibrating rod hose (b). S2. Insert the concrete pouring hose (c) and the vibrating rod hose (b) into the pipe body fixing frame. S3. Start the concrete pump truck and vibrator, so that the concrete pouring hose (c) continuously pours concrete and is lifted upward, and the vibrator hose (b) is lifted upward intermittently, so that the vibrator body (d) performs concrete vibration operation at the corresponding depth of all vibration layers. S4. The concrete pouring hose (c) and vibrator hose (b) are disconnected from the pipe fixing frame. The pipe fixing frame is removed from the pier formwork (a). After the concrete has cured and formed, the pier body is obtained. The structure of the pipe fixing frame includes a base plate (1) set on the upper edge of the pier template (a), a U-shaped steel (2) set on the upper surface of the base plate (1), a central ring unit (3) set on the base plate (1) and the U-shaped steel (2) for inserting the concrete pouring hose (c), a side base plate unit (4) set on the U-shaped steel (2) for installing the vibrator host (e) and the vibrator hose (b), and a support rod unit (5) screwed on the central ring unit (3) for reducing the bending amplitude of the vibrator hose (b).

2. The bridge pier manufacturing process according to claim 1, characterized in that: In S2, the number of concrete pouring hoses (c) is 1, and the number of vibrating rod hoses (b) is ≥4.

3. The bridge pier manufacturing process according to claim 1, characterized in that: In S3, the upward lifting method of the concrete pouring hose (c) is either continuous or intermittent.

4. The bridge pier manufacturing process according to claim 1, characterized in that: The side plate of the U-shaped steel (2) is provided with mounting holes (6). The middle ring unit (3) includes a ring body (301), a high rod (302) disposed on the outer ring surface of the ring body (301) and inserted into the mounting hole (6), and a support vertical plate (303) disposed on the outer ring surface of the ring body (301) and pressed on the upper surface of the bottom plate (1).

5. The bridge pier manufacturing process according to claim 1, characterized in that: The side base plate unit (4) includes a main base plate (401) disposed on the two U-shaped steels (2) and a hose limiting hole plate (402) disposed on the U-shaped steels (2).

6. The bridge pier manufacturing process according to claim 5, characterized in that: The main unit base plate (401) and the hose limiting hole plate (402) are respectively located on both sides of the pipe body fixing frame.

7. The bridge pier manufacturing process according to claim 4, characterized in that: The support rod unit (5) includes an internal threaded ring (501) disposed on the outer ring surface of the ring body (301), and a support rod body (502) disposed on the outer ring surface of the internal threaded ring (501) and used to lift and fix the vibrating rod hose (b).

8. The bridge pier manufacturing process according to claim 7, characterized in that: There are a total of 4 supporting vertical plates (303), which are set in pairs on the 2 base plates (1).

9. The bridge pier manufacturing process according to claim 8, characterized in that: The support rod unit (5) further includes a low-position screw hole plate (503) disposed on the outer ring surface of the inner threaded ring (501), and an adjusting bolt (504) disposed on the low-position screw hole plate (503) and used to fix the support rod body (502) by means of two support vertical plates (303) that are snapped together.

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