Segmental beam vertical precast formwork system and precasting method based on no matching beam

Abstract

The present application relates to the technical field of bridge construction, in particular to a segmental beam vertical prefabrication formwork system and prefabrication method based on non-matching beam. The formwork system comprises a bottom formwork module, a first side formwork module, a second side formwork module, a top formwork module and an inner formwork module. The bottom formwork module comprises a fixed bottom formwork fixed to the ground. The first side formwork module comprises a first side formwork frame arranged vertically on one side of the fixed bottom formwork and capable of vertical, horizontal and rotational adjustment. The second side formwork module comprises a second side formwork frame arranged vertically on the opposite side of the fixed bottom formwork relative to the first side formwork module and capable of horizontal adjustment. The top formwork module comprises a detachable movable top formwork connected to the top of the first side formwork frame and the second side formwork frame. The inner formwork module comprises a horizontally movable inner formwork frame and an inner formwork template connected to the inner formwork frame. The formwork system of the present application has simple structure, convenient operation, small site occupation area, high precision control, no need for traditional measurement operation, simplified prefabrication process and improved prefabrication efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of bridge construction, in particular to a segmental beam vertical prefabrication formwork system and prefabrication method based on non-matching beam. BACKGROUND

[0002] At present, segmental beams are mostly prefabricated by short-line matching method. The specific process is to set multiple pedestals in the prefabrication yard, and each pedestal is operated simultaneously. All beam segments are poured in movable shaped formworks. When pouring, a fixed formwork is arranged at one end of the beam segment to be poured, and the other end is the previously poured beam segment as a matching beam to ensure the splicing accuracy of adjacent blocks. After the pouring of the subsequent beam segment is completed and initial curing is performed, the previous beam segment is transported away for storage, and the newly poured beam segment is moved to its position. In the matching prefabrication process of the segmental beam, the previously poured beam segment is used as the movable end formwork of the beam segment to be poured, which can ensure the close fit between adjacent segments. However, at the same time, it will also cause some problems:

[0003] 1. High cost of site construction: high cost of foundation treatment and transfer equipment under the pedestal; large space requirement for steam curing kiln and high energy consumption;

[0004] 2. Not conducive to construction organization: the segmental beams in a prefabrication unit (such as a span bridge or a half-span bridge) need to be prefabricated in a certain order, and the entire production cycle is long, which is not conducive to construction organization.

[0005] To address the aforementioned technical issues, a Chinese invention patent with patent number "202110677616.2," entitled "A Precast Formwork System and Precast Method for Segmental Beams Based on Matching Beams," proposes a method for precasting segmental beams without matching beams. The formwork system described in this patent includes a fixed end mold, a movable end mold, an inner mold, and a bottom side mold. The fixed end mold and the movable end mold are located at both ends of the bottom side mold, and the three are spliced ​​together to form an internal space. The inner mold extends into the internal space, and its outer side is separated from the inner wall of the internal space by a certain distance, forming a casting space. The fixed end mold is fixedly installed, while the movable end mold can be adjusted in space by a movable adjustment device. The two end faces of the fixed end mold and the movable end mold near the bottom side mold respectively protrude and recess to form several matching shear keys and shear grooves. Prestressed duct positioning holes are also reserved on the fixed end mold and the movable end mold. This formwork system primarily utilizes pre-reserved shear keys and shear grooves on fixed and movable end molds to serve as matching beams. Once fabricated, the segmental beams can be immediately transferred to the beam storage area without serving as prefabrication templates for the next segmental beam, simplifying the process and allowing for beam storage two days earlier than traditional methods. However, this formwork system still has some drawbacks: it requires a large area, resulting in high site construction costs. The fixed and movable end molds are subjected to concrete compression forces during prefabrication, making their repositioning extremely difficult and requiring very high precision. Furthermore, demolding from this formwork system is quite challenging. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the aforementioned background technology and provide a segmental beam vertical precast formwork system and precasting method based on non-matching beams.

[0007] The technical solution of this invention is: a segmental beam vertical precast formwork system based on a non-matching beam, comprising,

[0008] Bottom formwork module, which is used to construct the longitudinal end face of the segmental beam, including a fixed bottom formwork fixed to the ground;

[0009] The first side formwork module is used to construct the bridge deck of the segmental beam, including a first side formwork frame that is vertically arranged on one side of the fixed bottom formwork and can be adjusted vertically, horizontally and rotatably;

[0010] The second side formwork module is used to construct the bottom surface of the segmental beam, including a horizontally adjustable second side formwork frame arranged vertically on the side of the fixed bottom formwork opposite to the first side formwork module;

[0011] Top formwork module, the top formwork module being used to construct the longitudinal end face of the segmental beam on the other side of the bridge, including a movable top formwork detachably connected to the top of the first side formwork frame and the second side formwork frame;

[0012] The inner mold module is used to construct the inner side of the beam hole of the segmental beam, and includes a horizontally movable inner mold frame and an inner mold template connected to the inner mold frame.

[0013] According to the segmental beam vertical precast formwork system based on non-matching beams provided in this application, the first side formwork module includes,

[0014] The first traveling track is arranged longitudinally on one side of the fixed bottom mold;

[0015] Side mold column, the side mold column is vertically arranged on the side of the first side mold frame facing away from the fixed bottom mold;

[0016] A vertical jack, the lower end of which is slidably connected to the first traveling track, and the upper end of which is fixedly connected to the lower end of the side mold column;

[0017] The longitudinal jack has its housing fixed on the first travel track, and its jacking end is connected to the vertical jack to drive the vertical jack and the side mold column to move longitudinally.

[0018] An angle adjustment device is provided between the side mold column and the first traveling track to drive the lower end of the side mold column to rotate around a horizontal transverse axis.

[0019] According to the segmental beam vertical precast formwork system based on a non-matching beam provided in this application, the angle adjustment device includes,

[0020] A sliding base is slidably connected to a first traveling track, and the lower end of the side mold column is hinged to the sliding base, which can rotate around a horizontal transverse axis.

[0021] The fixing frame is a triangular bracket installed on the side mold column and extending longitudinally away from the fixed bottom mold;

[0022] A telescopic hydraulic cylinder, one end of which is fixed on the first traveling track, and the other end of which is hinged to the top end of the fixed frame away from the side mold column and can rotate around the horizontal transverse axis.

[0023] According to the segmental beam vertical precast formwork system based on non-matching beams provided in this application, the second side formwork module includes,

[0024] The second traveling track is arranged longitudinally on the other side of the fixed bottom mold, and the second side mold frame is slidably connected to the second traveling track;

[0025] The limiting rod is a vertically arranged screw structure with external threads. The upper end of the limiting rod passes through the second side mold frame and is screwed to the screw hole on the second side mold frame. The lower end passes through the screw hole on the second travel track and is fixedly connected to the second travel track when fixing the second side mold frame.

[0026] According to the present application, a segmental beam vertical precast formwork system based on a non-matching beam is provided, wherein the movable top formwork is a plate-shaped structure with the same shape as the longitudinal end of the segmental beam, and multiple adjustment structures for adjusting the vertical height of the movable top formwork are provided between the outer edge of the movable top formwork and the first and second side formwork frames.

[0027] According to the segmental beam vertical precast formwork system based on a non-matching beam provided in this application, the adjustment structure includes,

[0028] A lead screw, which is arranged vertically and whose lower end is connected to a motor mounted on a first side mold frame or a second side mold frame;

[0029] A limiting plate, one end of which is connected to the outer edge of the movable top mold, and the other end extends outward in a horizontal direction. A slot for the lead screw to pass through is provided on the limiting plate.

[0030] The clamping nut includes an upper nut and a lower nut that are screwed onto the lead screw. The upper nut and the lower nut are respectively placed on the upper and lower sides of the limiting plate to fix the limiting plate to the lead screw in the vertical direction.

[0031] According to the present application, a segmental beam vertical precast formwork system based on a non-matching beam is provided, which further includes a shear key assembly for constructing the longitudinal end key teeth of the segmental beam; the shear key assembly includes a first shear key assembly fixed to the lower end face of the movable top formwork by a bolt structure and a second shear key assembly fixed to the upper end face of the fixed bottom formwork by a bolt structure.

[0032] According to the present application, a segmental beam vertical precast formwork system based on a non-matching beam is provided, which further includes a corrugated pipe for constructing prestressed ducts for the segmental beam; the corrugated pipe is arranged between the movable top mold and the fixed bottom mold, and the corrugated pipe is filled with an air-filled capsule.

[0033] This application also provides a method for vertical prefabrication of segmental beams, which employs a segmental beam vertical prefabrication formwork system based on unmatched beams, and is carried out according to the following steps:

[0034] S1. Install and fix the bottom mold, and adjust the positions of the first side mold frame and the second side mold frame to install them in the prefabricated position;

[0035] S2. Hoist the steel cage into the pouring space formed by the first and second side formwork, locate the prestressed ducts, and arrange the inner formwork.

[0036] S3. Hoist the movable top mold to the top of the first side mold frame and the second side mold frame, and adjust the position of the movable top mold to meet the prefabrication requirements;

[0037] S4. Segmental beam concrete is poured through the pouring holes on the movable top formwork and steam curing is carried out.

[0038] S5. After the curing meets the design requirements, remove the movable top formwork, open the first side formwork frame, move the second side formwork frame horizontally, demold the inner formwork template, and hoist the segmental beam to the beam storage area.

[0039] According to the segmental beam vertical prefabrication method provided in this application, the method for adjusting the position of the movable top mold in step S5 includes: arranging multiple motors on the first side mold frame and the second side mold frame, with vertical lead screws installed on the motors, and upper and lower nuts screwed onto the lead screws; after hoisting the movable top mold to the top of the first side mold frame and the second side mold frame, allowing the lead screw to pass through the slot on the limiting plate corresponding to the outer edge of the movable top mold, and adjusting the upper and lower nuts to fix the limiting plate and the lead screw in the vertical direction; the motor drives the lead screw to rotate to adjust the vertical height of the limiting plate, and the multiple motors work together to adjust the position of the movable top mold.

[0040] The advantages of this application are: 1. This application adopts a vertical method for prefabricating segmental beams, which completely eliminates the need for matching beams for matching manufacturing. The fixed bottom formwork and movable top formwork at the longitudinal end of the segmental beam will not bear the lateral pressure of the concrete, which greatly reduces the difficulty of adjusting the bottom formwork and top formwork, facilitates precise control and adjustment of the top formwork, eliminates the need for traditional measurement operations, simplifies the segmental beam prefabrication process, and improves production efficiency.

[0041] In addition, this application adopts a vertical casting mode, which occupies a very small area of ​​the site and can save on site construction costs, including the cost of foundation treatment under the platform and the cost of transfer equipment, reducing the space of the steam curing kiln and reducing energy consumption.

[0042] 2. The first side formwork of this application can be adjusted in height, horizontal and vertical angle. The adjustment method is simple, and the installation and demolding are extremely convenient. After demolding, the surface is smoother and there are no misalignments, resulting in better precast segmental beam quality.

[0043] 3. This application uses a telescopic hydraulic cylinder to adjust the angle of the first side formwork, making both installation and demolding of the first side formwork extremely convenient. The overall demolding operation of the first side formwork is extremely simple, resulting in higher quality precast segmental beams and significantly improved precast construction efficiency.

[0044] 4. The second side mold frame of this application slides along the second travel rail, which greatly facilitates the installation and demolding of the second side mold frame. In addition, after the second side mold frame is installed, it can be fixed on the second travel rail by the limit tie rod, making the installation and fixing extremely convenient.

[0045] 5. This application uses the adjustment structure below the movable top formwork to vertically adjust the movable top formwork, which can ensure the adjustment accuracy of the movable top formwork and make the longitudinal end face of the segmental beam fully meet the design requirements. Moreover, the adjustment method of this application is simple.

[0046] 6. This application uses a screw drive to adjust the position of the movable top mold. The adjustment operation of the movable top mold can be carried out by the motor driving the screw, which is extremely convenient. It can realize the vertical height adjustment and leveling operation of the movable top mold, which greatly improves the installation efficiency of the template.

[0047] 7. This application arranges shear key components on the fixed bottom formwork and the movable top formwork. The shear key components can form a key tooth structure at both ends of the segmental beam along the bridge direction. The key tooth structure formed by the shear key components does not require matching beams at all. Moreover, the shear key components can be configured according to requirements, which is simple to operate and has good adaptability.

[0048] 8. The positioning structure of the prestressed duct in this application is extremely simple and the operation is extremely convenient;

[0049] 9. The segmental beam prefabrication method of this application is extremely efficient, breaking away from the limitations of matching beams. It can perform classified prefabrication operations, reducing the amount of formwork adjustment, making the construction organization more flexible, and has low energy consumption and simple operation.

[0050] 10. The adjustment method of the movable top mold in this application is extremely convenient and the adjustment accuracy is extremely high. Through the cooperation of multiple motors and lead screws, the movable top mold can be quickly and accurately adjusted to the design requirements, greatly reducing the adjustment amount of the template.

[0051] The template system of this application has a simple structure, is easy to operate, occupies a small area, is easy to adjust, has high precision control, does not require traditional measurement work, simplifies the prefabrication process, improves prefabrication efficiency, and has great promotional value. Attached Figure Description

[0052] Figure 1 Elevation diagram of the template system in this application;

[0053] Figure 2 : A top view of the template system of this application;

[0054] Figure 3 : A schematic diagram of the active top mold structure of this application;

[0055] Figure 4 : A schematic diagram of the shear key assembly layout in this application;

[0056] Figure 5 : A schematic diagram of the shifting structure of this application;

[0057] Figure 6 This application pertains to the first step of the precast segmental beam construction (top view).

[0058] Figure 7 This application pertains to the first step of the precast segmental beam construction (side view).

[0059] Figure 8 This application pertains to the second step of the precast segmental beam construction (top view).

[0060] Figure 9 This application pertains to the second step of the precast segmental beam construction (side view).

[0061] Figure 10 This application pertains to the third step of the segmental beam prefabrication construction (top view).

[0062] Figure 11 This application pertains to the third step of the precast segmental beam construction (side view).

[0063] Figure 12 This application pertains to the fourth step of the segmental beam prefabrication construction (top view).

[0064] Figure 13 This application pertains to the fourth step of the segmental beam prefabrication construction (side view).

[0065] Figure 14 This application pertains to the fifth step of the segmental beam prefabrication construction (top view).

[0066] Figure 15 This application pertains to the fifth step of the segmental beam prefabrication construction (side view).

[0067] Figure 16 This application pertains to the sixth step of the segmental beam prefabrication construction (top view).

[0068] Figure 17 This application pertains to the sixth step of the segmental beam prefabrication construction (side view).

[0069] Figure 18 This application pertains to the seventh step of the segmental beam prefabrication construction (top view).

[0070] Figure 19 This application pertains to the seventh step of the segmental beam prefabrication construction (side view).

[0071] Wherein: 1—fixed bottom mold; 11—second shear key assembly;

[0072] 2—First side mold frame; 21—First traveling track; 22—Side mold column; 23—Vertical jack; 24—Longitudinal jack; 25—Sliding base; 26—Fixed frame; 27—Telescopic cylinder;

[0073] 3—Second side mold frame; 31—Second traveling track; 32—Limiting tie rod;

[0074] 4—Moving top mold; 41—Screw rod; 42—Motor; 43—Limit plate; 44—Bayonet; 45—Upper nut; 46—Lower nut; 47—First shear key assembly; 48—Pad plate;

[0075] 5—Inner mold frame; 6—Inner mold template; 7—Corrugated pipe; 8—Inflatable capsule. Detailed Implementation

[0076] Embodiments of the present invention are described in detail below, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0077] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "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.

[0078] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0079] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0080] This application relates to a vertical precast formwork system for segmental beams based on a non-matching beam. This formwork system can precast segmental beams vertically, meaning the precast segmental beams are vertical in the longitudinal direction and horizontal in the transverse direction. The advantages of this vertical precasting method are: extremely small precast site area; and simpler repositioning of the formwork at the longitudinal end of the segmental beam, as it does not bear lateral forces from the concrete, requiring only its own weight for repositioning. This results in less subsequent deformation, higher repositioning accuracy, and greater convenience. Furthermore, it reduces the space required for the curing kiln, thus reducing energy consumption.

[0081] Specifically, such as Figures 1-19 As shown, the template system of this application includes a bottom mold module, a first side mold module, a second side mold module, a top mold module, and an inner mold module. The bottom mold module is used to construct one end face of the segmental beam along the bridge direction and includes a fixed bottom mold 1 fixed to the ground. The fixed bottom mold 1 includes a bottom mold on a base plate fixed to the ground. The first side mold module is used to construct the bridge deck of the segmental beam and includes a first side mold frame 2 arranged vertically on one side of the fixed bottom mold 1, which can be adjusted vertically, horizontally, and rotatably. The first side mold frame 2 is installed and demolded through vertical, horizontal, and rotatable adjustments. The first side mold frame 2 constructs the bridge deck portion of the segmental beam. The inner side of the first side mold frame 2 is the bridge deck side mold template, which is a relatively flat plate-like structure. The second side formwork module is used to construct the bottom surface of the segmental beam. It includes a horizontally adjustable second side formwork frame 3, arranged vertically on one side of the fixed bottom formwork 1 opposite to the first side formwork module. The inner side of the second side formwork frame 3 is the bridge bottom side formwork template, which is a bent plate-like structure adapted to the bottom surface structure of the segmental beam. The top formwork module is used to construct the other end face of the segmental beam along the bridge direction. It includes a movable top formwork 4, which is detachably connected to the top of the first side formwork frame 2 and the second side formwork frame 3. The movable top formwork 4 is a detachable structure. During the prefabrication of the segmental beam, the movable top formwork 4 is hoisted for installation. After the segmental beam is prefabricated and cured, the movable top formwork 4 is removed. The inner formwork module is used to construct the inner surface of the beam opening of the segmental beam. It includes a horizontally movable inner formwork frame 5 and an inner formwork template 6 connected to the inner formwork frame 5.

[0082] The first side mold module and the second side mold module of this application are placed on both sides of the fixed bottom mold 1. The movable top mold 4 is installed on the upper end of the first side mold frame 2 and the second side mold frame 3. That is, the fixed bottom mold 1, the movable top mold 4, the first side mold module, the second side mold module and the inner mold module form the space for casting segmental beams. The inner mold module is located in the closed space formed by the fixed bottom mold 1, the movable top mold 4, the first side mold module and the second side mold module. In some cases, an end mold module is arranged between the first side mold module and the second side mold module.

[0083] The specific prefabrication method is carried out according to the following steps:

[0084] S1. Install and fix the fixed bottom mold 1, and adjust the positions of the first side mold frame 2 and the second side mold frame 3 to install them in the prefabricated position, such as... Figures 6-9 As shown;

[0085] The first side mold frame 2 can be installed in place by rotating, translating and vertically moving, and the second side mold frame 3 can be installed in place by translating. After installation, the first side mold frame 2 and the second side mold frame 3 are fixed and locked.

[0086] S2. Hoist the reinforcing cage into the pouring space formed by the first side formwork 2 and the second side formwork 3, locate the prestressed ducts, and arrange the inner formwork 6, as follows. Figures 10-13 As shown;

[0087] The inner mold template 6 is supported by the inner mold frame 5. The lower end of the inner mold frame 5 is equipped with a roller structure, which can be adjusted in position. The inner mold template 6 is connected to the inner mold frame 5 through an adjusting rod.

[0088] S3. Hoist the movable top mold 4 to the top of the first side mold frame 2 and the second side mold frame 3, and adjust the position of the movable top mold 4 to meet the prefabrication requirements, such as... Figures 14-15 As shown;

[0089] S4. The segmental beam concrete is poured through the pouring holes on the movable top formwork 4, and steam curing is carried out, such as... Figures 16-17 As shown;

[0090] S5. After curing meets design requirements, remove the movable top formwork 4, open the first side formwork 2, move the second side formwork 3 horizontally, and demold the inner formwork 6. Figures 18-19 As shown, the segmental beams are hoisted to the beam storage area.

[0091] The segmental beams in this application are cast vertically, and demolding is done as a whole. This involves first demolding the movable top formwork 4, then the inner formwork, followed by the side formwork, and finally hoisting it away from the bottom formwork. This whole-body demolding method is simple, results in a smooth surface for the segmental beams after demolding, and improves the precast quality of the segmental beams.

[0092] In some embodiments of this application, the first side mold module described above has been optimized, specifically, as follows: Figures 1-2As shown, the first side formwork module includes a first traveling track 21, a side formwork column 22, a vertical jack 23, a longitudinal jack 24, and an angle adjustment device. The first traveling track 21 is arranged longitudinally on one side of the fixed bottom formwork 1 and is a track structure laid on the ground of the prefabrication site. The side formwork column 22 is vertically arranged on the side of the first side formwork frame 2 facing away from the fixed bottom formwork 1, and the side formwork column 22 is equivalent to the supporting skeleton of the first side formwork frame 2. The lower end of the vertical jack 23 is slidably connected to the first traveling track 21, and the upper end is fixedly connected to the lower end of the side formwork column 22. The vertical jack 23 is used to adjust the height of the entire first side formwork frame 2. The bridge deck side formwork is installed on the first side formwork frame 2, which means that the height of the bridge deck side formwork can be adjusted using the vertical jack 23. The housing of the longitudinal jack 24 is fixed on the first traveling track 21. The jacking end is connected to the vertical jack 23 to drive the vertical jack 23 and the side mold column 22 to move longitudinally. The longitudinal jack 24 is used to adjust the longitudinal position of the first side mold frame 2 for installation or demolding operations. The angle adjustment device between the side mold column 22 and the first traveling track 21 is used to drive the lower end of the side mold column 22 to rotate around the horizontal axis. The angle adjustment device can cooperate with the longitudinal jack 24 to perform demolding and installation operations of the bridge deck side mold.

[0093] In a further embodiment of this application, the angle adjustment device described above has been optimized, specifically, as follows: Figure 1 As shown, the angle adjustment device includes a sliding base 25, a fixed frame 26, and a telescopic cylinder 27. The sliding base 25 is slidably connected to the first traveling track 21. The lower end of the side mold column 22 is hinged to the sliding base 25 and can rotate around the horizontal axis. The lower end of the side mold column 22 is hinged to the sliding base 25, so the first side mold frame 2 can realize the adjustment of the rotation angle. Based on the hinge structure at the lower end, the first side mold frame 2 can be flipped longitudinally towards the inner mold frame 5 or away from the inner mold frame 5. It cooperates with the longitudinal jack 24 to realize the demolding or installation of the first side mold frame 2.

[0094] The fixed frame 26 is a triangular bracket installed on the side mold column 22 and extending longitudinally away from the fixed bottom mold 1. One end of the telescopic cylinder 27 is fixed on the first traveling track 21, and the other end is hinged to the top end of the fixed frame 26 away from the side mold column 22, which can rotate around the horizontal axis. In this embodiment, a guide structure is provided between the fixed frame 26 and the telescopic cylinder 27. The guide structure is a sleeve-type structure, including a sleeve and a guide rod. The sleeve is hinged to the housing of the telescopic cylinder 27, which can rotate around the horizontal axis. The guide rod is sleeved inside the sleeve, which can extend and retract along its axial direction. The free end of the guide rod is hinged to the top end of the fixed frame 26 away from the side mold column 22, and the pushing end of the telescopic cylinder 27 is hinged to the guide rod. The telescopic cylinder 27 drives the guide rod to extend and retract within the sleeve, thereby cooperating with the longitudinal jack 24 to adjust the rotation angle of the first side mold frame 2.

[0095] In other embodiments of this application, the second side mold module described above has been optimized, specifically, as follows: Figures 1-2 As shown, the second side mold module includes a second traveling track 31 and a limiting rod 32. The second traveling track 31 is arranged longitudinally on the other side of the fixed bottom mold 1. The second side mold frame 3 is slidably connected to the second traveling track 31. During installation and demolding, the second side mold frame 3 can be driven to move longitudinally along the second traveling track 31. The second traveling track 31 and the first traveling track 21 are respectively placed on the longitudinal sides of the fixed bottom mold 1. The limiting rod 32 is a vertically arranged screw structure with external threads. The upper end of the limiting rod 32 passes through the second side mold frame 3 and is screwed to the screw hole on the second side mold frame 3. The lower end passes through the screw hole on the second traveling track 31 and is fixedly connected to the second traveling track 31 when the second side mold frame 3 is fixed.

[0096] When the second side mold frame 3 needs to be installed, it can be driven to move along the second travel track 31 to the set position. Then, the limiting rod 32 is passed through the screw holes on the second side mold frame 3 and the second travel track 31. By tightening the corresponding nut structure, the limiting rod 32 is tensioned, and the second side mold frame 2 can be stably fixed on the second travel track 31. When the second side mold frame 3 needs to be demolded, the limiting rod 32 is removed, the connection between the second side mold frame 2 and the second travel track 31 is released, and the second side mold frame 3 is moved to complete the demolding operation of the second side mold frame 3.

[0097] In a further embodiment of this application, the above-mentioned movable top mold 4 has been optimized, specifically, as follows: Figure 3 As shown, the movable top mold 4 is a plate-shaped structure with the same shape as the longitudinal end of the segmental beam. Multiple casting holes are evenly distributed on the movable top mold 4. Multiple adjustment structures for adjusting the vertical height of the movable top mold 4 are provided between the outer edge of the movable top mold 4 and the first side mold frame 2 and the second side mold frame 3.

[0098] Specifically, such as Figure 5 As shown, the adjustment structure includes a lead screw 41, a limiting plate 43, and a clamping nut. The lead screw 41 is arranged vertically, and its lower end is connected to a motor 42 mounted on the first side mold frame 2 or the second side mold frame 3. One end of the limiting plate 43 is connected to the outer edge of the movable top mold 4, and the other end extends outward in a horizontal direction. The limiting plate 43 has a slot 44 for the lead screw 41 to pass through. The slot 44 is a U-shaped groove, and the lead screw 41 can enter the slot 44 horizontally from the opening side of the slot 44. The clamping nut includes an upper nut 45 and a lower nut 46 screwed onto the lead screw 41. The upper nut 45 and the lower nut 46 are respectively placed on the upper and lower sides of the limiting plate 43 to fix the limiting plate 43 to the lead screw 41 in a vertical direction. A pad 48 is also provided on the lead screw 41, and the upper nut 45 and the lower nut 46 are each equipped with a corresponding pad 48.

[0099] After the movable top mold 4 is hoisted to the top of the first side mold frame 2 and the second side mold frame 3, the lead screw 41 is aligned with the limiting plate 43 one by one. The lead screw 41 enters the corresponding slot 44, and the limiting plate 43 is located between the upper nut 45 and the lower nut 46. The upper nut 45 and the lower nut 46 are rotated to fix the limiting plate 43. After all the lead screws 41 are fixedly connected with the limiting plate 43, the lead screw 41 is driven to move vertically by the motor 42. Multiple motors 42 operate in coordination to realize the adjustment operation of the movable top mold 4.

[0100] In other embodiments of this application, the template system of this embodiment further includes shear key fittings for constructing the longitudinal end keys of the segmental beam, such as... Figure 4 As shown, the shear key assembly includes a first shear key assembly 47 fixed to the lower end face of the movable top mold 4 by a bolt structure and a second shear key assembly 11 fixed to the upper end face of the fixed bottom mold 1 by a bolt structure.

[0101] The first shear key assembly 47 and the second shear key assembly 11 are respectively installed on the movable top mold 4 and the fixed bottom mold 1, which can form the required key tooth structure at the longitudinal end of the segmental beam. The first shear key assembly 47 and the second shear key assembly 11 are adjustable and detachable structures, so their positions can be adjusted according to the requirements.

[0102] In some embodiments of this application, the template system of this embodiment further includes a corrugated pipe 7 for constructing prestressed ducts in segmental beams, such as... Figure 4 As shown, the bellows 7 is arranged between the movable top mold 4 and the fixed bottom mold 1, and the bellows 7 is filled with an inflatable capsule 8.

[0103] The vertical direction of this application is Figure 1 The left and right directions in the middle, and the horizontal direction is Figure 1The direction perpendicular to the paper, vertical refers to Figure 1 The up and down directions.

[0104] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A segmental beam vertical precast formwork system based on non-matching beams, characterized in that: include, Bottom formwork module, the bottom formwork module is used to construct the longitudinal end face of the segmental beam, including a fixed bottom formwork (1) fixed to the ground. The first side formwork module is used to construct the bridge deck of the segmental beam, including a first side formwork frame (2) that is vertically, horizontally and rotatably adjustable and arranged on one side of the fixed bottom formwork (1). The second side formwork module is used to construct the bottom surface of the segmental beam, including a second side formwork frame (3) that is vertically arranged on the side of the fixed bottom formwork (1) relative to the first side formwork module and is adjustable in the horizontal direction. The top formwork module is used to construct the segmental beam on the other side of the bridge along the direction of the bridge, including a movable top formwork (4) that is detachably connected to the top of the first side formwork (2) and the second side formwork (3). The inner mold module is used to construct the inner side of the beam hole of the segmental beam, including a horizontally movable inner mold frame (5) and an inner mold template (6) connected to the inner mold frame (5). The movable top mold (4) is a plate-shaped structure with the same shape as the end of the segmental beam along the bridge direction. Multiple adjustment structures for adjusting the vertical height of the movable top mold (4) are provided between the outer edge of the movable top mold (4) and the first side mold frame (2) and the second side mold frame (3). The adjustment structure includes: A lead screw (41) is arranged vertically, and its lower end is connected to a motor (42) installed on the first side mold frame (2) or the second side mold frame (3). The limiting plate (43) is connected at one end to the outer edge of the movable top mold (4) and at the other end extends outward in the horizontal direction. The limiting plate (43) has a slot (44) for the lead screw (41) to pass through. The clamping nut includes an upper nut (45) and a lower nut (46) that are screwed onto the lead screw (41). The upper nut (45) and the lower nut (46) are respectively placed on the upper and lower sides of the limiting plate (43) to fix the limiting plate (43) to the lead screw (41) in the vertical direction.

2. The segmental beam vertical precast formwork system based on a non-matching beam as described in claim 1, characterized in that: The first side module includes, The first traveling track (21) is arranged longitudinally on one side of the fixed bottom mold (1); Side mold column (22), the side mold column (22) is vertically arranged on the side of the first side mold frame (2) facing away from the fixed bottom mold (1); A vertical jack (23) is slidably connected at its lower end to the first traveling track (21) and fixedly connected at its upper end to the lower end of the side mold column (22). The longitudinal jack (24) has its housing fixed on the first traveling track (21), and its jacking end is connected to the vertical jack (23) to drive the vertical jack (23) and the side mold column (22) to move longitudinally. An angle adjustment device is provided between the side mold column (22) and the first travel track (21) to drive the lower end of the side mold column (22) to rotate around the horizontal transverse axis.

3. The segmental beam vertical precast formwork system based on a non-matching beam as described in claim 2, characterized in that: The angle adjustment device includes, The sliding base (25) is slidably connected to the first traveling track (21), and the lower end of the side mold column (22) is hinged to the sliding base (25) so that it can rotate around the horizontal transverse axis. The fixing frame (26) is a triangular bracket installed on the side mold column (22) and extending longitudinally away from the fixed bottom mold (1); Telescopic cylinder (27), one end of which is fixed on the first travel track (21), and the other end is hinged to the top end of the fixed frame (26) away from the side mold column (22) and can rotate around the horizontal transverse axis.

4. The segmental beam vertical precast formwork system based on a non-matching beam as described in claim 2, characterized in that: The second side mold module includes, The second traveling track (31) is arranged longitudinally on the other side of the fixed bottom mold (1), and the second side mold frame (3) is slidably connected to the second traveling track (31); The limiting rod (32) is a vertically arranged screw structure with external threads. The upper end of the limiting rod (32) passes through the second side mold frame (3) and is screwed to the screw hole on the second side mold frame (3). The lower end passes through the screw hole on the second travel track (31) and is fixedly connected to the second travel track (31) when fixing the second side mold frame (3).

5. The segmental beam vertical precast formwork system based on a non-matching beam as described in claim 1, characterized in that: It also includes shear key fittings for constructing the longitudinal end key teeth of the segmental beam; the shear key fittings include a first shear key fitting (47) fixed to the lower end face of the movable top mold (4) by bolt structure and a second shear key fitting fixed to the upper end face of the fixed bottom mold (1) by bolt structure.

6. The segmental beam vertical precast formwork system based on a non-matching beam as described in claim 1, characterized in that: It also includes a corrugated pipe (7) for constructing prestressed ducts for segmental beams; the corrugated pipe (7) is arranged between the movable top mold (4) and the fixed bottom mold (1), and the corrugated pipe (7) is filled with an air-filled capsule (8).

7. A method for vertical prefabrication of segmental beams, characterized in that: The segmental beam vertical precast formwork system based on any one of claims 1 to 6 is adopted and the following steps are performed: S1. Install and fix the fixed bottom mold (1), and adjust the positions of the first side mold frame (2) and the second side mold frame (3) to install them in the prefabricated position; S2. Hoist the steel cage into the pouring space formed by the first side formwork (2) and the second side formwork (3), locate the prestressed ducts, and arrange the inner formwork (6). S3. Hoist the movable top mold (4) to the top of the first side mold frame (2) and the second side mold frame (3), and adjust the position of the movable top mold (4) to meet the prefabrication requirements; S4. Segmental beam concrete is poured through the pouring hole on the movable top formwork (4) and steam curing is carried out. S5. After the curing meets the design requirements, remove the movable top formwork (4), open the first side formwork (2), move the second side formwork (3), demold the inner formwork (6), and hoist the segment beam to the beam storage area.

8. The method for vertical prefabrication of segmental beams as described in claim 7, characterized in that: In step S5, the method for adjusting the position of the movable top mold (4) includes: arranging multiple motors (42) on the first side mold frame (2) and the second side mold frame (3), installing vertical lead screws (41) on the motors (42), and sleeved with an upper nut (45) and a lower nut (46) that are spirally connected to the lead screw (41); after hoisting the movable top mold (4) to the top of the first side mold frame (2) and the second side mold frame (3), allowing the lead screw (41) to pass through the slot (44) on the limiting plate (43) corresponding to the outer edge of the movable top mold (4), adjusting the upper nut (45) and the lower nut (46) to fix the limiting plate (43) and the lead screw (41) in the vertical direction; the motors (42) drive the lead screw (41) to rotate to adjust the vertical height of the limiting plate (43), and the multiple motors (42) work together to adjust the position of the movable top mold (4).

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