Support system and construction method of water super-long light surface concrete cast-in-place structure beam

Abstract

The application discloses a support system of an overwater super-long smooth concrete cast-in-situ structure beam and a construction method thereof, which comprises two engineering piles standing underwater and extending out of the water surface, a concrete pile cap and a one-meter beam end on the concrete pile cap, a hanging form H-shaped steel is installed on the one-meter beam end, each hanging form H-shaped steel is connected with a beam bottom supporting H-shaped steel through a high-strength screw rod, steel plate corbels are welded on steel casings of the engineering piles, and inclined supporting channel steels are welded between the steel plate corbels and the beam bottom supporting H-shaped steel, two inclined supporting channel steels connected with two steel plate corbels of the same engineering pile are arranged in parallel and connected into a whole through a plurality of equidistant connecting screw rods. The application ensures the stable stress of the overall support of the super-long component through the mode of upward pulling and downward supporting, improves the safety of the construction support system of the overwater super-long cast-in-situ beam component and the quality of the concrete appearance, makes the construction simple, and provides construction efficiency.

Description

Technical Field

[0001] This invention relates to the field of water-based construction technology, and more particularly to the field of construction technology for cast-in-place ultra-long concrete beams in water-based structures. It describes a novel support system for ultra-long cast-in-place beams on water where the beam base cannot be placed on mud. This method can also be used for high-altitude ultra-long cast-in-place structural beams. The concrete in this area has a fair-faced finish. Specifically, it is a support system and construction method for ultra-long smooth-surface cast-in-place concrete structural beams on water. Background Technology

[0002] The support method for ultra-long cast-in-place concrete beams in underwater engineering is generally used in construction projects on water. When constructing underwater structures, if a silt surface is used as the bearing layer of the support system, the uprights are affected by the tidal influence of the seawater. In addition to the load from the superstructure construction, the uprights are also subjected to the horizontal thrust of the seawater. The impact of the tidal force varies depending on the location and length of the uprights. During the superstructure construction, the superposition of these two forces makes it difficult to ensure the overturning resistance and structural shape retention of the frame. This can easily lead to frame collapse or eccentric deformation of the concrete during pouring, resulting in poor structural integrity. Summary of the Invention

[0003] The purpose of this invention is to provide a support system and construction method for ultra-long cast-in-place smooth concrete structural beams above water, to solve the problems of uneven bearing capacity and construction difficulties caused by underwater silt surfaces, thereby improving construction safety and stability, and enhancing the appearance quality of the smooth concrete beams. This invention achieves its purpose through the following technical solutions:

[0004] A support system for an ultra-long, smooth-surface concrete cast-in-place structural beam on water includes: two engineering piles spaced a certain distance apart, a concrete cap at the top of the engineering piles, and a one-meter beam end on the concrete cap. The one-meter beam end consists of two pre-cast beams extending one meter from each end of the engineering pile on both the inner and outer sides. The inner ends of the two one-meter beam ends form the casting position for the structural beam. The bottom of the engineering piles is underwater, and their upper parts extend above the water surface. Two parallel hanging formwork I-beams are installed on the portion of each one-meter beam end extending inwards from the engineering pile. The length direction of the hanging formwork I-beams is perpendicular to the length direction of the one-meter beam end, and both ends of the hanging formwork I-beams extend forward and backward from the edges of the one-meter beam end. A beam bottom support I-beam is installed below the casting position of the structural beam, with both ends of the beam bottom support I-beam located below the two one-meter beam ends. Each hanging formwork I-beam is supported by a high... The high-strength screw is connected to the I-beam supporting the bottom of the beam; the lower part of the high-strength screw is the free end for mounting bolts; the outer side of the engineering pile is covered with a steel casing, and two steel plate brackets are welded to the steel casings of the two engineering piles at the same height. The steel plate brackets are located below the height of the I-beam supporting the bottom of the beam. The two steel plate brackets on the same engineering pile are located on the front and rear sides of the engineering pile, respectively. Each steel plate bracket is welded to the I-beam supporting the bottom of the beam with a diagonal support channel steel. The top of the diagonal support channel steel is welded to the I-beam supporting the bottom of the beam through an accessory steel plate, and the bottom of the diagonal support channel steel is welded to the steel plate bracket; the two diagonal support channel steels connected to the two steel plate brackets of the same engineering pile are arranged in parallel, and the two parallel diagonal support channel steels are connected by multiple equally spaced connecting screws; the upper part of the I-beam supporting the bottom of the beam is sequentially equipped with a timber backing and a beam bottom template.

[0005] As an optimization of the installation position of the steel plate bracket, the height of the steel plate bracket is 300mm above the water surface; in a seawater environment, it is installed 300mm above the low tide level to ensure it is not affected by seawater tides. Considering the possibility of welding construction, and the fact that tidal waves are generally 100-300mm, a certain distance is maintained from the water surface during welding construction to ensure that there is no leakage or electric shock accident.

[0006] As an optimization of the inclined support, the angle between the inclined support channel steel and the engineering pile is 45 to 60 degrees.

[0007] The construction method for the support system of the ultra-long cast-in-place smooth concrete structural beam on the water involves first constructing and curing the concrete cap of the engineering piles and the one-meter beam end on the water to the design strength, and then using a suspended formwork method to construct the ultra-long cast-in-place structural beam. The construction of the support system includes the following steps:

[0008] Step 1: Determine the required material length and specifications based on the height, width, and length of the cast-in-place structural beam, as well as the diameter of the engineering piles and the height of the piles above the water surface.

[0009] Step 2: Install a hanging formwork I-beam perpendicular to the beam direction on the end of the one-meter beam, and install a vertically downward high-strength bolt to connect it to the supporting I-beam at the bottom of the beam;

[0010] Step 3: Based on the height of the cast-in-place structural beam, install and adjust the height of the bottom support I-beam. When the height of the bottom support I-beam is appropriate, connect and tighten the high-strength bolts with bolts. Install the wooden back ribs and bottom formwork on the upper part of the bottom support I-beam in sequence.

[0011] Step 4: Above the water surface of the engineering pile, weld steel plate brackets onto the outer steel casing of the engineering pile according to the dimensions and width of the I-beam supporting the bottom of the beam; calculate and select the support point of the inclined support channel steel at the bottom of the I-beam supporting the bottom of the beam based on the length of the cast-in-place structural beam, and determine the length of the inclined support channel steel.

[0012] Step 5: Weld an additional steel plate to the upper end of the inclined support channel steel, adjust the angle of the inclined support channel steel so that the top additional steel plate intersects with the position of the bottom support I-beam of the beam, and the bottom intersects with the steel plate bracket. Then weld the additional steel plate to the bottom I-beam of the beam, and weld the bottom of the inclined support channel steel to the steel plate bracket.

[0013] Step Six: Based on the width of the inclined support channel steel, select a connecting bolt of suitable length. Drill a hole every 1 meter on the inclined support channel steel to ensure the connecting bolt can pass through. Connect the two inclined support channel steels with the connecting bolt to form a closed whole. This design ensures stability and consistent overall dimensions, preventing misalignment and facilitating installation.

[0014] Construction principle of this invention: This invention is applicable to cast-in-place beams longer than 6 meters, where the end caps of the beam have been completed and the last meter of the beam has been poured to the design strength. This invention uses a suspended formwork system at the last meter of the beam end to fix the bottom formwork in a suitable position. Considering that the support system for ultra-long cast-in-place beams cannot guarantee bending resistance solely through suspended formwork at both ends, a diagonal channel steel support system is installed on the engineering piles. The top of the support reaches the lower part of the I-beam at the bottom of the beam, and the bottom reaches the pile body, thus achieving stability for the ultra-long beam. This invention transfers the beam load to the end caps and engineering piles to achieve a stable support system; by reinforcing the bottom support I-beam through top-pull and bottom-bracing, ultra-long cast-in-place beams on water can be constructed in a simple way, while ensuring a safe environment and stability during formwork construction.

[0015] The advantages and beneficial effects of this invention are:

[0016] This invention utilizes the pre-cast foundations at both ends of the beam as support points for the suspended formwork system. Simultaneously, diagonal steel supports are installed above the water surface of the engineering piles, forming an upward-pull and downward-bracing support system for the beam. This simplifies the construction of ultra-long cast-in-place beams and ensures the stability of the support system under stress.

[0017] Once the support in the upper construction area is stable, it can be ensured that the subsequent formwork laying will not be deformed or fall apart due to the horizontal thrust of seawater tides, thereby achieving the appearance quality of the smooth concrete beam. Attached Figure Description

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments:

[0019] Figure 1 This is a schematic longitudinal section of the support system for the ultra-long smooth concrete cast-in-place structural beam on water, as described in this invention.

[0020] Figure 2 This is a schematic cross-sectional view of the support system for the ultra-long smooth concrete cast-in-place structural beam on water, as described in this invention.

[0021] Figure 3 This is a schematic diagram of the fixed points of the inclined support channel steel at the bottom of the engineering pile in this invention;

[0022] Figure 4 This is a three-dimensional schematic diagram of the fixing points of the inclined support channel steel at the bottom of the engineering pile in this invention;

[0023] Figure 5 This is a schematic diagram of the connection plane between the inclined support channel steel of the I-beam at the bottom of the beam in this invention;

[0024] Figure 6 This is a three-dimensional schematic diagram of the connection between the I-beam at the bottom of the beam and the inclined support channel steel in this invention.

[0025] Attached diagram labels: 1. Engineering pile; 2. Concrete pile cap; 3. One-meter beam end; 4. Cast-in-place structural beam; 5. Steel plate corbel; 6. Diagonal support channel steel; 7. Beam bottom support I-beam; 8. High-strength bolt; 9. Hanging formwork I-beam; 10. Steel casing; 11. Connecting bolt; 12. Additional steel plate; 13. Timber back rib; 14. Beam bottom formwork. Figure 1 The 1000 in the figure represents 1000 mm; Figure 2 , 4 In this context, 200 represents 200mm and 100 represents 100mm. Detailed Implementation

[0026] Example 1:

[0027] To make the technical means, innovative features, objectives and effects of this invention easier to understand, the invention will be further described below.

[0028] The embodiments described herein are specific implementations of the present invention, used to illustrate the concept of the invention, and are illustrative and exemplary, and should not be construed as limiting the implementation or scope of the invention. In addition to the embodiments described herein, those skilled in the art can employ other obvious technical solutions based on the content disclosed in the claims and specification of this application. These technical solutions include those that make any obvious substitutions and modifications to the embodiments described herein.

[0029] In the description of this invention, it should be noted that the terms "upper", "lower", "inner", "outer", "front", "rear", 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.

[0030] like Figure 1 , 2 As shown, a support system for an ultra-long smooth concrete cast-in-place structural beam on water includes: two engineering piles 1 spaced a certain distance apart, a concrete cap 2 set at the upper end of the engineering piles 1, and a one-meter beam end 3 on the concrete cap 2. The one-meter beam end 3 is a cast-in-place beam that extends 1 meter from the inner and outer sides of the engineering piles 1 at both ends. The inner ends of the one-meter beam ends 3 of the two engineering piles are the casting position of the cast-in-place structural beam 4. The bottom of the engineering piles 1 is located underwater and its upper part extends above the water surface. "Ultra-long" means that the distance between the centers of the two engineering piles 1 is not less than 8m and the length of the cast-in-place structural beam 4 is not less than 6m.

[0031] like Figure 1 , 2As shown, two parallel hanging formwork I-beams 9 are installed on the portion of each one-meter beam end 3 extending inward toward the engineering pile 1. The length direction of the hanging formwork I-beams 9 is set perpendicular to the length direction of the one-meter beam end 3, and both ends of the hanging formwork I-beams 9 extend outward from the front and rear sides of the one-meter beam end 3. A beam bottom support I-beam 7 is set below the casting position of the cast-in-place structural beam 4, and both ends of the beam bottom support I-beam 7 are located below the two one-meter beam ends 3 respectively. Each hanging formwork I-beam 9 is connected to the beam bottom support I-beam 7 by a high-strength bolt 8. The lower part of the high-strength bolt 8 is the free end for mounting bolts. Two hanging formwork I-beams 9 are set at the end 3 of the beam on the same side with a spacing of 200mm. Each hanging formwork I-beam 9 extends 500mm from each side of the beam. The hanging formwork I-beam 9 on the outer side is no less than 200mm from the edge of the foundation, and the hanging formwork I-beam 10 on the inner side is no less than 200mm from the inner end of the end 3 of the beam. Each hanging formwork I-beam 9 has a vertically downward high-strength bolt 8 installed on both the front and rear sides at a distance of no less than 100mm from its end. The end of the bottom I-beam 7 of the beam needs to be 100mm from the two sides of the concrete foundation for easy removal later.

[0032] like Figure 3 , 4 As shown, the outer side of the engineering pile 1 is covered with a steel casing 10. Two steel plate brackets 5 are welded to the steel casings 10 of the two engineering piles 1 at the same height. The steel plate brackets 5 are located below the height of the bottom support I-beam 7 of the beam. The two steel plate brackets 5 on the same engineering pile 1 are located on the front and rear sides of the engineering pile 1. Figure 5 , 6 As shown, each steel plate bracket 5 is welded to the bottom support I-beam 7 with a diagonal support channel steel 6. The top of the diagonal support channel steel 6 is welded to the bottom support I-beam 7 via an accessory steel plate 12, and the bottom of the diagonal support channel steel 6 is welded to the steel plate bracket 5. The two diagonal support channel steels 6 connected to the two steel plate brackets 5 of the same engineering pile 1 are arranged in parallel, and the two parallel diagonal support channel steels 6 are connected by multiple equally spaced connecting bolts 11. The height of the steel plate bracket 5 is 300mm above the water surface. In a seawater environment, it is installed 300mm above the low tide level.

[0033] The angle between the inclined support channel steel 6 and the engineering pile 1 is 45-60 degrees, which allows the inclined support channel steel to better transfer the load of the cantilever beam. Timber back ribs 13 and beam bottom formwork 14 are sequentially installed on the upper part of the beam bottom support I-beam 7.

[0034] In this embodiment, an I-beam 1 meter wider than the beam width is selected as the hanging formwork I-beam 9. The bottom support I-beam 7 is connected to the hanging formwork I-beam 9 by high-strength bolts 8 to form the main body of the support system. Then, inclined support channel steel 6 is installed on the corbel of the engineering pile and welded to the bottom I-beam 7 to form a support system with upper pull and lower support.

[0035] In this embodiment, the construction method of the support system for the ultra-long smooth concrete cast-in-place structural beam on the water involves first constructing and curing the concrete cap and one-meter beam end of the underwater engineering pile to the design strength, and then using a suspended formwork method to construct the ultra-long cast-in-place structural beam. The construction of the support system includes the following steps:

[0036] Step 1: Based on the height, width, and length of the cast-in-place structural beam 4, as well as the diameter of the engineering pile 1 and the height of the pile above the water surface, determine the required length and specifications of the materials.

[0037] Step 2: Install a hanging formwork I-beam 9 perpendicular to the beam direction on the end 3 of the 1-meter beam, and install a vertically downward high-strength bolt 8 to connect with the bottom support I-beam 7 of the beam;

[0038] Step 3: Based on the height of the cast-in-place structural beam 4, install and adjust the height of the bottom support I-beam 7. When the height of the bottom support I-beam 7 is appropriate, connect and tighten the high-strength bolts 8 with bolts. Install the wooden back ribs 13 and the bottom formwork 14 on the upper part of the bottom support I-beam 7 in sequence.

[0039] Step 4: Above the water surface of pile 1, weld steel plate brackets 5 onto the outer steel casing 10 of pile 1 according to the dimensions and width of the I-beam 7 supporting the beam bottom (the width between two steel plate brackets on the same pile should be compatible with the width of the I-beam supporting the beam bottom); calculate and select the support point of the inclined support channel steel 6 at the bottom of the I-beam 7 based on the length of the cast-in-place structural beam 4, and determine the length of the inclined support channel steel 6; in this embodiment, the dimensions of the steel plate bracket 5 are 200mm x 200mm x 12mm, and the steel plate bracket 5 and the steel casing 10 are fully welded on both sides;

[0040] Step 5: Weld an additional steel plate 12 to the upper end of the inclined support channel steel 6, adjust the angle of the inclined support channel steel 6 so that the top additional steel plate 12 intersects with the position of the bottom support I-beam 7 and the bottom intersects with the steel plate bracket 5, then weld the additional steel plate 12 to the bottom support I-beam 7 and weld the bottom of the inclined support channel steel 6 to the steel plate bracket 5.

[0041] Step 6: Based on the width of the inclined support channel steel 6, select a connecting bolt 11 of suitable length. Drill a hole every 1 meter on the inclined support channel steel to ensure that the connecting bolt 11 can pass through. Connect the two inclined support channel steels 6 with the connecting bolt 11 to form a closed whole. In this embodiment, an M14 connecting bolt 11 is set every 1 meter. The additional steel plate has a size of 400mm long x 80mm wide x 12mm thick.

[0042] This invention utilizes I-beams suspended at the beam ends and inclined supports installed on engineering piles to simplify and enhance the support system for ultra-long cast-in-place concrete beams in water, making the operation safer and more convenient. By using an upward-pulling and downward-bracing method, the overall support stability of the ultra-long component is ensured, replacing the original practice of setting up a support system on the muddy surface at the bottom of the water. This invention improves the safety of the support system for ultra-long cast-in-place beams in water, enhances the appearance quality of the concrete, and increases the ease of construction, significantly improving the construction efficiency of cast-in-place components in water.

Claims

1. A support system for an ultra-long, smooth-surface concrete cast-in-place structural beam for use on water, comprising: Two engineering piles (1) spaced a certain distance apart, a concrete cap (2) set on the upper end of the engineering piles (1), and a one-meter beam end (3) on the concrete cap (2). The one-meter beam end (3) is a cast-in-place beam with two ends extending 1 meter from the inner and outer sides of the engineering piles (1). The inner ends of the one-meter beam ends (3) of the two engineering piles (1) are the casting positions of the cast-in-place structural beam (4). The bottom of the engineering piles (1) is underwater and its upper part extends above the water surface. The feature is that: Two parallel hanging formwork I-beams (9) are installed on the part of each one-meter beam end (3) extending into the engineering pile (1). The length direction of the hanging formwork I-beams (9) is set to be perpendicular to the length direction of the one-meter beam end (3). The two ends of the hanging formwork I-beams (9) extend out of the front and rear sides of the one-meter beam end (3). A beam bottom support I-beam (7) is set below the casting position of the cast-in-place structural beam (4). The two ends of the beam bottom support I-beam (7) are respectively located below the two one-meter beam ends (3). Each hanging formwork I-beam (9) is connected to the beam bottom support I-beam (7) through a high-strength screw (8). The lower part of the high-strength screw (8) is the free end of the mounting bolt. The outer side of the engineering pile (1) is covered with a steel casing (10). The steel casings (10) of the two engineering piles (1) are each welded with two steel plate brackets (5) at the same height. The steel plate brackets (5) are located below the height of the beam bottom support I-beam (7). The two steel plate brackets (5) on the same engineering pile (1) are located on the front and rear sides of the engineering pile (1) respectively. Each steel plate bracket (5) is welded to the beam bottom support I-beam (7) with a diagonal support channel steel (6). The top of the diagonal support channel steel (6) is welded to the beam bottom support I-beam (7) through an additional steel plate (12), and the bottom of the diagonal support channel steel (6) is welded to the steel plate bracket (5). The two diagonal support channel steels (6) connected to the two steel plate brackets (5) of the same engineering pile (1) are arranged in parallel, and the two parallel diagonal support channel steels (6) are connected by multiple equally spaced connecting bolts (11). The upper part of the bottom support I-beam (7) is sequentially equipped with a wooden back brace (13) and a bottom formwork (14).

2. The support system for an ultra-long smooth concrete cast-in-place structural beam on water as described in claim 1, characterized in that: The height of the steel plate bracket (5) is 300mm above the water surface; when in a seawater environment, it is installed 300mm above the low tide level.

3. The support system for an ultra-long, smooth concrete cast-in-place structural beam on water as described in claim 1, characterized in that: The angle between the inclined support channel steel (6) and the engineering pile (1) is 45~60 degrees.

4. The support system for an ultra-long smooth concrete cast-in-place structural beam on water as described in claim 1, characterized in that: The distance between the centers of the two engineering piles (1) shall not be less than 8m, and the length of the cast-in-place structural beam (4) shall not be less than 6m.

5. The support system for an ultra-long smooth concrete cast-in-place structural beam on water as described in claim 1, characterized in that: Two hanging formwork I-beams (9) are set at the same one-meter beam end (3) with a spacing of 200mm. Each hanging formwork I-beam (9) extends 500mm from each side of the beam. The hanging formwork I-beam (9) on the outer side is not less than 200mm from the edge of the bearing platform, and the hanging formwork I-beam (9) on the inner side is not less than 200mm from the inner end of the one-meter beam end (3). Each hanging formwork I-beam (9) has a vertically downward high-strength screw (8) installed on both the front and rear sides at a distance of not less than 100mm from its end.

6. The construction method of the support system for the ultra-long cast-in-place smooth concrete structural beam above water as described in claim 1, wherein after the concrete foundation of the engineering pile and the one-meter beam end above water are constructed and cured to the design strength, the ultra-long cast-in-place structural beam is constructed by means of suspended formwork. The construction of the support system includes the following steps: Step 1: Based on the height, width, and length of the cast-in-place structural beam (4), the diameter of the engineering pile (1), and the height of the pile above the water surface, determine the required material length and specifications. Step 2: Install a hanging formwork I-beam (9) perpendicular to the beam direction on the end (3) of the one-meter beam, and install a vertically downward high-strength screw (8) to connect with the bottom support I-beam (7); Step 3: Based on the height of the cast-in-place structural beam (4), install and adjust the height of the bottom support I-beam (7). When the height of the bottom support I-beam (7) reaches the required height, connect and tighten the high-strength screw (8) with bolts. Install the wooden back rib (13) and the bottom formwork (14) on the upper part of the bottom support I-beam (7) in sequence. Step 4: Above the water surface of the engineering pile (1), weld steel plate brackets (5) onto the outer steel casing (10) of the engineering pile (1) according to the size and width of the I-beam (7) supporting the bottom of the beam; calculate and select the support point of the inclined support channel steel (6) at the bottom of the I-beam (7) supporting the bottom of the beam according to the length of the cast-in-place structural beam (4), and determine the length of the inclined support channel steel (6); Step 5: Weld an additional steel plate (12) to the upper end of the inclined support channel steel (6), adjust the angle of the inclined support channel steel (6), and make the position of the top additional steel plate (12) intersect with the position of the bottom support I-beam (7) and the bottom intersect with the steel plate bracket (5). Then weld the additional steel plate (12) to the bottom support I-beam (7) and weld the bottom of the inclined support channel steel (6) to the steel plate bracket (5). Step 6: Based on the width of the inclined support channel steel (6), select a connecting screw (11) of suitable length, and make a hole every 1 meter on the inclined support channel steel to ensure that the connecting screw (11) can pass through. Use the connecting screw (11) to connect the two inclined support channel steels (6) to form a closed whole.

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