A steel tower manufacturing process, a cable-stayed bridge construction process, a steel tower and a cable-stayed bridge

Abstract

The application provides a steel tower manufacturing process, a cable-stayed bridge construction process, a steel tower and a cable-stayed bridge, and relates to the technical field of cable-stayed bridges, and comprises the following steps: steel tower segment block: S1. Each steel tower segment comprises all or part of four box bodies, namely, a side box chamber, a side anchor chamber, a middle anchor chamber and an anchor box; box body assembly: S2. The side box chamber, the side anchor chamber, the middle anchor chamber and the anchor box are respectively assembled by adopting a long line method; box body transfer: S3. The assembled side box chamber, side anchor chamber, middle anchor chamber and anchor box are transferred to a general assembly site; and three-dimensional general assembly of the steel tower segment. The side box chamber, the side anchor chamber, the middle anchor chamber and the anchor box are respectively assembled by adopting the long line method, so that the linear type of the individual box body can be effectively controlled. Furthermore, when the three-dimensional general assembly of the steel tower segment is performed, the problems of steel tower linear type control, steel tower box opening size control and welding deformation control are solved, and the installation precision after the three-dimensional general assembly of the steel tower is ensured.

Description

Technical Field

[0001] This invention relates to the field of cable-stayed bridge technology, and more specifically, to a steel tower manufacturing process, a cable-stayed bridge construction process, a steel tower, and a cable-stayed bridge. Background Technology

[0002] In recent years, my country has made tremendous achievements in bridge construction, with a large number of large bridges featuring novel structures and high technological content transforming natural barriers into thoroughfares. However, prior to the construction of the Nanjing Yangtze River Bridge, the towers of large suspension bridges and cable-stayed bridges were all constructed using reinforced concrete structures.

[0003] For steel towers with constantly changing cross-sections, the outer tower wall panels are welded with full penetration welding, and the stiffening ribs are bolted together, requiring high manufacturing precision. Therefore, ensuring the steel tower assembly alignment and achieving smooth erection and installation is a crucial focus. Summary of the Invention

[0004] The problem solved by this invention is to provide a steel tower manufacturing process to improve the accuracy of the alignment during the three-dimensional assembly of the steel tower and ensure the smooth erection of the steel tower.

[0005] To address the above problems, the present invention provides a steel tower manufacturing process, comprising:

[0006] S1. Divide the steel tower into multiple steel tower segments, and further divide each steel tower segment into blocks. After the blocks are formed, each steel tower segment includes all or part of the four boxes: side box chamber, side anchor chamber, middle anchor chamber, and anchor box.

[0007] Box assembly: S2. The side box chamber, the side anchor chamber, the middle anchor chamber, and the anchor box are assembled separately using the long-line method;

[0008] Container Transfer: S3. Transfer the assembled side box chamber, side anchor chamber, middle anchor chamber, and anchor box to the final assembly site;

[0009] Three-dimensional assembly of steel tower segments: S4. Install the side anchor chambers on both sides of the central anchor chamber, and install the side box chambers on the side of the side anchor chambers away from the central anchor chamber;

[0010] Steel tower three-dimensional assembly: S5. The steel tower segments are assembled sequentially from bottom to top using a hoisting method.

[0011] Optionally, the plurality of steel tower segments include standard segments and non-standard segments. The standard segments include segments No. 3, No. 4, No. 5, No. 6, No. 7, No. 8, No. 9 and No. 10, and the non-standard segments include segments No. 1, No. 2, No. 11, No. 12 and No. 13.

[0012] Optionally, the assembly process of the side chamber includes:

[0013] Process 1. The side chambers on the steel tower segment are manufactured on a special jig;

[0014] Process 2. The multiple side chambers are pre-assembled according to the assembly sequence of the steel tower segments using the long-line method, and the specific pre-assembly rounds are determined according to the size of the workshop site;

[0015] Process 3. After each round of pre-assembly is completed, the side box chambers are disassembled. After disassembly, the last section of the side box chamber is used as the parent beam to participate in the next round of assembly. The remaining side box chambers are transported to the main assembly site for three-dimensional assembly of steel tower segments.

[0016] Optionally, the assembly process of the side anchor chamber includes:

[0017] Process 1. The side anchor chambers on the steel tower segment are manufactured on a special jig, and the anchor boxes are assembled on the side anchor chambers;

[0018] Process 2. The multiple side anchor chambers are pre-assembled using the long-line method according to the assembly sequence of the steel tower segments, and the specific pre-assembly rounds are determined according to the size of the workshop site;

[0019] Process 3. After each round of pre-assembly is completed, the side anchor chamber is disassembled. After disassembly, the last section of the side anchor chamber is used as the mother beam to participate in the next round of assembly. The remaining side anchor chambers are transported to the main assembly site for three-dimensional assembly of steel tower segments.

[0020] Optionally, the assembly process of the middle anchor chamber includes:

[0021] Process 1. The central anchor chamber on the steel tower segment is manufactured on a special jig, and the anchor box is assembled on the central anchor chamber;

[0022] Step 2. The multiple anchor chambers are pre-assembled using the long-line method according to the assembly sequence of the steel tower segments, and the specific pre-assembly rounds are determined according to the size of the workshop site.

[0023] Process 3. After each round of pre-assembly is completed, the middle anchor chamber is disassembled. After disassembly, the last section of the middle anchor chamber is used as the mother beam to participate in the next round of assembly. The remaining middle anchor chambers are transported to the general assembly site for three-dimensional assembly of steel tower segments.

[0024] Optionally, step S5 specifically includes five rounds of assembly: In the first round of assembly, segment 1 and segment 2 are rigidly connected to the support pier; then, segment 1 and segment 2 are used as parent segments to sequentially assemble segment 3, segment 4, and segment 5; In the second round of assembly, segment 5 is used as the parent segment to sequentially assemble segment 6 and segment 7; In the third round of assembly, segment 7 is used as the parent segment to sequentially assemble segment 8 and segment 9; In the fourth round of assembly, segment 9 is used as the parent segment to sequentially assemble segment 10 and segment 11; In the fifth round of assembly, segment 11 is used as the parent segment to sequentially assemble segment 12 and segment 13.

[0025] Optionally, during the first round of assembly, the centerline positions of the first segment and the second segment are first determined before assembly, and then the third segment and the fourth segment are assembled sequentially from left to right or from right to left.

[0026] A construction process for a cable-stayed bridge, using the steel tower manufacturing process described above.

[0027] A steel tower manufactured using the steel tower manufacturing process described above.

[0028] A cable-stayed bridge is manufactured using the steel tower manufacturing process described above, and / or using the cable-stayed bridge construction process described above, and / or includes the steel towers described above.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] The steel tower is divided into multiple steel tower segments, and each segment is further divided into blocks. Each steel tower segment includes all or part of four boxes: side box chambers, side anchor chambers, middle anchor chambers, and anchor boxes. The side box chambers, side anchor chambers, middle anchor chambers, and anchor boxes are assembled separately using a long-line method. This ensures effective control over the alignment of each individual box. Furthermore, the four independent boxes are assembled together during the three-dimensional assembly of the steel tower segments. This solves the problems of steel tower alignment control, box opening size control, and welding deformation control. Moreover, after the steel tower is divided into blocks, alignment adjustment and control are most effective during the three-dimensional assembly of the steel tower. Alignment adjustments can be made through individual boxes, preventing movement of other alignments and ensuring installation accuracy after the three-dimensional assembly of the steel tower. Attached Figure Description

[0031] Figure 1 A flowchart of the steel tower manufacturing process according to an embodiment of the present invention;

[0032] Figure 2This is a schematic diagram of the steel tower structure according to an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the structure of segment 1 and segment 2 in the steel tower of an embodiment of the present invention;

[0034] Figure 4 This is a schematic diagram of the structure of segment 3 and segment 4 in the steel tower of an embodiment of the present invention;

[0035] Figure 5 This is a schematic diagram of the structure of segment five in the steel tower according to an embodiment of the present invention;

[0036] Figure 6 This is a schematic diagram of the structure of segment six in the steel tower according to an embodiment of the present invention;

[0037] Figure 7 This is a schematic diagram of the structure of segment seven in the steel tower according to an embodiment of the present invention;

[0038] Figure 8 This is a schematic diagram of the structure of segment eight in the steel tower according to an embodiment of the present invention;

[0039] Figure 9 This is a schematic diagram of the structure of segment nine in the steel tower according to an embodiment of the present invention;

[0040] Figure 10 This is a schematic diagram of the structure of segment 10 in the steel tower according to an embodiment of the present invention;

[0041] Figure 11 This is a schematic diagram of the structure of segment eleven in the steel tower according to an embodiment of the present invention;

[0042] Figure 12 This is a schematic diagram of the structure of segment 12 in the steel tower according to an embodiment of the present invention;

[0043] Figure 13 This is a schematic diagram of the structure of segment thirteen in the steel tower according to an embodiment of the present invention;

[0044] Figure 14 This is a front view of the steel tower according to an embodiment of the present invention;

[0045] Figure 15 This is a schematic diagram of the three-dimensional assembly of the steel tower in the steel tower manufacturing process of an embodiment of the present invention;

[0046] Figure 16 This is a schematic diagram of the segmented structure of the steel tower in the steel tower manufacturing process according to an embodiment of the present invention;

[0047] Figure 17 This is a flowchart illustrating the pre-assembly of multiple side chambers using the long-line method according to the assembly sequence of steel tower segments in the steel tower manufacturing process of this invention.

[0048] Figure 18 This is a flowchart illustrating the pre-assembly of multiple side anchor chambers using the long-line method according to the assembly sequence of steel tower segments in the steel tower manufacturing process of this invention.

[0049] Figure 19 This is a schematic diagram of the installation of the anchor box and side anchor chamber in the steel tower manufacturing process of an embodiment of the present invention;

[0050] Figure 20 This is a schematic diagram of the installation of the anchor box and the middle anchor chamber in the steel tower manufacturing process of an embodiment of the present invention;

[0051] Figure 21 This is a schematic diagram of the three-dimensional assembly of the steel tower in the steel tower manufacturing process of an embodiment of the present invention.

[0052] Explanation of reference numerals in the attached figures:

[0053] 1. Side box chamber; 2. Side anchor chamber; 3. Middle anchor chamber; 4. Anchor box; ST1, segment 1; ST2, segment 2; ST3, segment 3; ST4, segment 4; ST5, segment 5; ST6, segment 6; ST7, segment 7; ST8, segment 8; ST9, segment 9; ST10, segment 10; ST11, segment 11; ST12, segment 12; ST13, segment 13. Detailed Implementation

[0054] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] It should be noted that in the XYZ coordinate system provided in this article, the positive X-axis represents the right, the negative X-axis represents the left, the positive Y-axis represents the back, the negative Y-axis represents the front, the positive Z-axis represents the top, and the negative Z-axis represents the bottom.

[0056] Combination Figure 1 , Figure 2 , Figures 14-16 and Figure 21 As shown, an embodiment of the present invention provides a steel tower manufacturing process, including:

[0057] S1. Divide the steel tower into multiple steel tower segments, and further divide each steel tower segment into blocks. After the blocks are formed, each steel tower segment includes all or part of the four boxes: side box chamber 1, side anchor chamber 2, middle anchor chamber 3, and anchor box 4.

[0058] Box assembly: S2. The side box chamber 1, side anchor chamber 2, middle anchor chamber 3 and anchor box 4 are assembled separately using the long line method;

[0059] Container transfer: S3. Transfer the assembled side box chamber 1, side anchor chamber 2, middle anchor chamber 3 and anchor box 4 to the final assembly site;

[0060] Three-dimensional assembly of steel tower segments: S4. Install side anchor chambers 2 on both sides of the central anchor chamber 3, and install side box chambers 1 on the side of the side anchor chamber 2 away from the central anchor chamber 3;

[0061] Steel tower three-dimensional assembly: S5. The steel tower segments are assembled sequentially from bottom to top using a hoisting method.

[0062] In this embodiment, firstly, the steel tower is divided into multiple steel tower segments, and each steel tower segment is further divided into blocks. Each steel tower segment includes all or part of four boxes: side box chamber 1, side anchor chamber 2, middle anchor chamber 3, and anchor box 4. The side box chamber 1, side anchor chamber 2, middle anchor chamber 3, and anchor box 4 are assembled separately using the long-line method. The primary goal is to ensure that the alignment of each individual box can be effectively controlled.

[0063] Secondly, the advantage of manufacturing four independent boxes is that dividing a steel tower segment into four separate individuals can speed up the manufacturing cycle and is not limited by site and equipment. Moreover, compared to transporting steel tower segments, transporting each independent box to the assembly site before assembling the steel tower segment is more conducive to module transportation and can improve transportation efficiency.

[0064] Secondly, treating the steel tower segments as planar assembly and matching large steel box girders helps control assembly errors between segments. Furthermore, the welding of the segmented steel tower sections largely changes from overhead welding to vertical welding, significantly accelerating welding efficiency. Most importantly, the installation and positioning of anchor boxes 4, manufactured and installed separately and using anchor plate alignment for positioning, effectively improves the accuracy of anchor box 4 positioning and installation. Segmented manufacturing of the steel tower allows for effective control of welding deformation. Moreover, segmented manufacturing makes alignment adjustment and control most effective during three-dimensional assembly; alignment adjustments can be made individually to prevent movement of other alignments.

[0065] It should be noted that the three-dimensional assembly of the steel tower segments specifically includes: placing the central anchor chamber 3 on the jig and measuring its verticality, box opening size, etc., to confirm that its dimensions are correct; installing the two side anchor chambers 2; after installing the side anchor chambers 2, it is necessary to confirm whether the relative positions of the side anchor chambers 2 are correct, and the installation position of the anchor box 4 needs to be re-measured to prevent any deviation in the position of the anchor box 4; installing the two side box chambers 1, and then measuring their box opening size, anchor box 4 positioning, gaps between wall panels, etc., and after confirming that everything is correct, welding all the welds according to the welding process.

[0066] In summary, the steel tower manufacturing process provided by this invention can improve the accuracy of the alignment during the three-dimensional assembly of the steel tower, ensuring the smooth erection of the steel tower.

[0067] Optionally, combined Figures 2-13 As shown, the multiple steel tower segments include standard segments and non-standard segments. The standard segments include segment 3 (ST3), segment 4 (ST4), segment 5 (ST5), segment 6 (ST6), segment 7 (ST7), segment 8 (ST8), segment 9 (ST9), and segment 10 (ST10). The non-standard segments include segment 1 (ST1), segment 2 (ST2), segment 11 (ST11), segment 12 (ST12), and segment 13 (ST13).

[0068] Specifically, the steel tower is composed of segments ST1 to ST13 from bottom to top. The standard section consists of segments ST3 to ST10. The standard section is divided into four parts: side box chamber 1, side anchor chamber 2, middle anchor chamber 3, and anchor box 4. It should be noted that the cross-section of the standard section is composed of two heptagons combined to form a fourteen-sided shape, and the cross-section decreases continuously from segment ST3 to segment ST10.

[0069] The manufacturing process of segments ST1 and ST2 in the non-standard section is as follows: First, process partitions or fixing devices are added to the steel-concrete section, and the steel-concrete section is assembled on the jig; a pressure plate is installed on the steel-concrete section, ensuring a tight fit between the pressure plate and the steel-concrete section; N9 and N10 anchor plates are installed on the pressure plate; partitions are installed from the middle to both sides; transverse wall panels on both sides are installed, ensuring a tight fit between them and the pressure plate; longitudinal wall panels on both sides are installed, ensuring a tight fit between them and the pressure plate; transverse inclined wall panels are installed; lateral longitudinal wall panels, small compartment partitions, and stiffening ribs are installed; finally, manhole reinforcing rings and small anchor chamber units are installed.

[0070] Manufacturing process of segments ST11 (No. 11) and ST12 (No. 12) in the non-standard section: Since one of the upper side anchor plates is reduced, segments ST11 and ST12 are divided into three boxes for matching manufacturing. When the segments are divided into three boxes for matching manufacturing, the anchor box 4 of the side anchor chamber 2 is only welded to the side of the side anchor plate. Then, a temporary positioning device is installed for positioning to ensure that the anchor box 4 will not be deformed or displaced during transportation.

[0071] The manufacturing process of segment ST13 (the 13th segment) in the non-standard section: Since segment ST13 (the 13th segment) does not have anchor box 4, it is assembled and welded directly in the workshop according to the box-type rod manufacturing plan, and then directly sent to the three-dimensional assembly to match the port.

[0072] Optionally, combined Figures 16-20 As shown, the assembly process of side chamber 1 includes:

[0073] Process 1. The side chamber 1 on the steel tower segment is manufactured on a special jig;

[0074] Process 2. Pre-assemble multiple side chambers 1 using the long-line method according to the assembly sequence of the steel tower segments. Determine the specific pre-assembly rounds based on the size of the workshop space, referring to... Figure 17 As shown;

[0075] Process 3. After each round of pre-assembly is completed, the side box chamber 1 is disassembled. After disassembly, the last section of side box chamber 1 is left as the parent beam to participate in the next round of assembly. The remaining side box chambers 1 are all transported to the main assembly site for three-dimensional assembly of steel tower segments.

[0076] Side box chamber 1, side anchor chamber 2, middle anchor chamber 3, and anchor box 4 are all assembled in the workshop. After the side box chamber 1 is prepared, multiple side box chambers 1 can be pre-assembled according to the assembly sequence of the steel tower segments using the long-line method. This allows for the pre-verification of the preparation accuracy and assembly progress of multiple side box chambers 1 along the assembly sequence of the steel tower segments, ensuring the accuracy of the alignment during the three-dimensional assembly of the steel tower, and ensuring the assembly accuracy and efficiency of the subsequent three-dimensional assembly of the steel tower segments and the three-dimensional assembly of the steel tower at the assembly site.

[0077] Due to the limited size of the workshop, the length of the workshop may not be able to accommodate the entire length of the pre-assembled side box chamber 1. In this case, the pre-assembly can be carried out in multiple rounds according to the sequence of the steel tower segments. The next round is pre-assembled using the parent beam left over from the previous round as a standard.

[0078] Specifically, process 1 above includes:

[0079] Process 1.1 Erect a formwork according to the alignment of the steel tower sidewall panels, and set longitudinal and transverse baselines and measurement points;

[0080] Step 1.2 On the jig, according to the partition spacing, first place the partition unit vertically. The partition unit should be perpendicular to the jig. After positioning, fix the partition on the jig.

[0081] Process 1.3: Construct one side wall panel unit according to the frame line, then fix the side wall panel unit on the partition, and measure the line of the side wall panel unit;

[0082] Step 1.4 Weld the other side panel unit, fix the side panel unit to the partition, and measure the line shape of the side panel unit and whether the two side panel units are joined together;

[0083] In process 1.5, assemble the two side wall panel units, paying attention to checking the perpendicularity between the vertical wall panels, partitions, and side wall panels. After passing the inspection, perform tack welding, and then weld the welds between the partitions and side wall panels, the vertical wall panels and side wall panels, and the partitions and vertical wall panels in sequence. After passing the non-destructive testing, perform correction.

[0084] Specifically, in the assembly process of side chamber 1, in process 1.1, a horizontal jig is fabricated according to the site sample. After the jig is manufactured, it is measured and inspected to ensure that it is a horizontal jig. Then, the jig is erected linearly. In process 1.2, the partitions should be installed perpendicular to the flat assembly jig. During installation, a tolerance of +2mm to +3mm should be reserved between the partitions. If the partitions are installed perpendicularly to the jig, the overall line of side chamber 1 will be slanted upwards. In process 1.3, special attention should be paid to the relative position between the side wall panels and the partitions during installation, especially the end partitions and the wall panels. The relative positional deviation between the panels must not exceed 2mm. Excessive deviation will lead to inaccurate panel alignment during final assembly, affecting overall dimensional accuracy. After installation, the side wall panels should first be spot-welded to the partitions, without welding the welds between the partitions and the wall panels initially. Welding should be done symmetrically after assembly. In process 1.4, during the installation of this side wall panel, pay close attention to the alignment of the wall panel stiffening ribs with the partition grooves. If there is interference, timely inspection and adjustment are necessary to avoid installation errors. After installation, check for lateral bending of the welds between this side wall panel and the other side wall panel. If twisted, this side panel needs to be removed, adjusted, and reinstalled (to prevent defects during welding, the panel's verticality must be ensured). After installation, continue adjusting the relative position between the end partition and the side panel. After the side panel is installed, first spot weld it to the partition, without welding the weld between the partition and the side panel. Weld symmetrically after assembly. In process 1.5, when assembling the two transverse side panels, pay attention to the alignment between the transverse side panels and the side panel, ensuring the gap between them is not too large. In process 2, after assembly, it is necessary to... On the side wall panels, the center point of the partition is reversed to the outside of the side wall panels. This allows for easy measurement and verification of the steel tower dimensions from all aspects during the final assembly. By using the long-line method for pre-assembly, the matching accuracy requirements between steel tower segments can be met, thus ensuring the linear accuracy of the steel tower during the three-dimensional final assembly. After assembly, the matching parts for planar assembly need to be installed for quick positioning during final assembly. The matching parts are positioned in the middle of the two side wall panels. In process 3, the beam transport trolley is used for demolding. After demolding, the demolding is directly transferred to the sand room for sandblasting and coating. After sandblasting and coating are completed, the three-dimensional final assembly of the steel tower segments is carried out.

[0085] Optionally, combined Figures 16-20 As shown, the assembly process of side anchor chamber 2 includes:

[0086] Process 1. The side anchor chambers 2 on the steel tower segment are manufactured on a special jig, and the four anchor boxes are assembled onto the side anchor chambers 2, refer to... Figure 19 As shown;

[0087] Procedure 2. Pre-assemble multiple side anchor chambers 2 using the long-line method according to the assembly sequence of the steel tower segments. Determine the specific pre-assembly rounds based on the size of the workshop area, referring to... Figure 18As shown;

[0088] Process 3. After each round of pre-assembly is completed, the side anchor chamber 2 is disassembled. After disassembly, the last section of side anchor chamber 2 is left as the mother beam to participate in the next round of assembly. The remaining side anchor chambers 2 are all transported to the general assembly site for three-dimensional assembly of steel tower segments.

[0089] After the side anchor chamber 2 is prepared, multiple side anchor chambers 2 can be pre-assembled using the long-line method according to the assembly sequence of the steel tower segments. This allows for the pre-verification of the preparation accuracy and assembly progress of multiple side anchor chambers 2 along the assembly sequence of the steel tower segments, ensuring the accuracy of the alignment during the three-dimensional assembly of the steel tower, and ensuring the assembly accuracy and efficiency of the subsequent three-dimensional assembly of the steel tower segments and the three-dimensional assembly of the steel tower at the assembly site.

[0090] Due to the limited size of the workshop, the length of the workshop may not be able to accommodate the entire length of the pre-assembled side anchor chamber 2. In this case, the pre-assembly can be carried out in multiple rounds according to the sequence of the steel tower segments. The next round is pre-assembled using the parent beam left over from the previous round as a standard.

[0091] Specifically, process 1 above includes:

[0092] Process 1.1 Construct two sets of special splicing frames for the side anchor chambers according to the wall panel line shape, and set longitudinal and transverse baselines and measurement points;

[0093] Procedure 1.2: Hoist the upper anchor plate unit into the leveled assembly jig, align the longitudinal baseline of the anchor plate with the longitudinal baseline of the jig, and after adjustment, mark the assembly system lines of the transverse partition and anchor box 4.

[0094] Process 1.3. Assemble anchor box 4 along the line. Carefully check whether the positioning dimensions of anchor box 4 meet the requirements of the process drawings. After confirming that there are no errors, spot weld anchor box 4 and anchor plate to fix them.

[0095] Step 1.4 Assemble the transverse diaphragms along the lines, paying attention to checking the perpendicularity of the transverse diaphragms to the anchor plates. Once correct, spot weld them in place.

[0096] Step 1.5 Install the lower anchor plate unit. After verifying that its dimensions are correct, weld the welds between the anchor plate and the partition plate, as well as between the anchor plate and the anchor box 4. After the welds pass the non-destructive testing, they are corrected.

[0097] Process 1.6 Assemble the wall panel units on both sides of the line. Pay attention to checking the verticality, box opening size and diagonal difference between the partition, wall panel and anchor plate. After confirming that there are no errors, spot weld them in place. Weld the welds between the partition and anchor plate, the wall panel and anchor plate and the partition and wall panel in sequence. After the welds pass the non-destructive testing, they are corrected.

[0098] Step 1.7 Turn the side anchor chamber 2 over, install the upper side diaphragm unit after turning it over, and spot weld it in place after confirming that its size is correct;

[0099] Step 1.8 Install the upper side wall panel unit. After installation, check its dimensions for errors. After confirming that there are no errors, weld the weld between the upper partition and the upper side wall panel. After the weld passes the inspection, it is corrected.

[0100] Process 1.9 Install the inclined wall panel units on both sides. After installation, check whether there are any errors in their dimensions. After confirming that there are no errors, weld the weld between the upper inclined wall panel and the partition. After the weld is inspected and qualified, it is corrected.

[0101] Specifically, in the assembly process of the side anchor chamber 2, in process 1.1, a horizontal jig is made according to the ground sample. After the jig is manufactured, it is measured and inspected to ensure that it is a horizontal jig. Then, the jig is erected linearly. In process 1.2, before the anchor plate unit is assembled in the plane, it needs to be widened. The anchor plate needs to be turned over during the widening process, and safety should be taken into account during the turning. In process 1.3, the anchor box 4 installed at this time only needs to be installed with a "well" structure. The anchor pipe is not installed yet. The anchor pipe is installed after the plane assembly is completed. When positioning and installing the anchor box 4, it is necessary to... To determine the anchor point coordinates, the coordinates should be calculated and provided based on the actual assembly sequence. During the positioning of anchor box 4, the coordinates of the intersection point between the anchor box 4 support plate and the anchor plate also need to be provided. After installing the upper anchor plate in process 1.5, weld the penetration weld between anchor box 4 and the anchor plate, and weld all the welds between the partition plate and the anchor plate. When installing the upper anchor plate, pay attention to the perpendicularity and parallelism of the upper and lower anchor plates. The diagonal difference of the box opening should not exceed 2mm. The assembly reference sides must be aligned to ensure they are not uneven. If, during assembly, it is found that the anchor plate unit itself is flat... If the surface area is insufficient, it needs to be readjusted before installation. If, during the installation of the upper anchor plate, the weight of the anchor plate causes the partition to twist or deform, vertical supports need to be added inside the box chamber. Temporary supports are made of structural steel and installed vertically 300mm from the end of each side anchor chamber 2 to adjust the opening size of the side anchor chamber 2. Temporary supports must be installed on both sides, especially for anchor chambers with single partitions. When the side anchor chamber 2 is assembled into this form in process 1.6, it allows for turning over; therefore, at this time, the wall panels and anchors need to be... All welds on the plates are performed using submerged arc welding. Welding that requires flipping is performed. In process 1.7, anchor pipes can be inserted before or after the installation of the upper component of the anchor plate. After inserting the anchor pipe, the angle of the anchor pipe needs to be positioned and adjusted. After the angle of the anchor pipe is adjusted to the correct position, it is first tack welded and fixed, and then welded sequentially from the inside to the outside. The angle deviation of the anchor pipe must not exceed 0.1°. In process 1.8, the weld between the upper side wall plate and the lower side wall plate is welded during the three-dimensional assembly. At this time, only the welds between the upper side wall plate and the partition plate, and between the upper partition plate and the anchor plate need to be welded. When installing the upper side panel and partition, the flatness of the upper side panel and the lower side panel needs to be adjusted. On the reference side, the upper side panel and the lower side panel need to be aligned without any deviation. On the cutting side, the overall cutting is carried out after the overall assembly is completed. In process 2, after the assembly is completed, the anchor points of the anchor box 4 must be reversed to the outside of the two transverse side panels to prevent the anchor points from being re-measured during the subsequent three-dimensional assembly and to measure the anchor point position during the erection. After the plane assembly is completed, the matching parts of the plane assembly need to be installed so that the positioning can be quickly achieved during the final assembly. By using the long line method for pre-assembly, the matching accuracy requirements between steel tower segments can be met, thereby ensuring the linear accuracy of the steel tower during the three-dimensional final assembly. The matching parts are positioned and installed on the side panels and anchor plates. In process 3, the beam transport trolley is used for demolding. After demolding, the steel tower segments are directly transported to the sand room for sandblasting and coating. After the sandblasting and coating are completed, the three-dimensional final assembly of the steel tower segments is carried out.

[0102] Optionally, optional, combined Figures 16-20 As shown, the assembly process of the middle anchor chamber 3 includes:

[0103] Process 1. The central anchor chamber 3 on the steel tower segment is manufactured on a dedicated jig, and the four anchor boxes are then assembled onto the central anchor chamber 3, as per the reference. Figure 20 As shown;

[0104] Process 2. Pre-assemble multiple intermediate anchor chambers 3 according to the assembly sequence of steel tower segments using the long-line method, and determine the specific pre-assembly rounds based on the size of the workshop site;

[0105] Process 3. After each round of pre-assembly is completed, the middle anchor chamber 3 is disassembled. After disassembly, the last section of the middle anchor chamber 3 is left as the mother beam to participate in the next round of assembly. The remaining middle anchor chambers 3 are all transported to the general assembly site for three-dimensional assembly of steel tower segments.

[0106] After the preparation of the middle anchor chamber 3 is completed, multiple middle anchor chambers 3 can be pre-assembled according to the assembly sequence of the steel tower segments using the long-line method. This allows for the pre-verification of the preparation accuracy and assembly progress of multiple middle anchor chambers 3 along the assembly sequence of the steel tower segments, ensuring the accuracy of the alignment during the three-dimensional assembly of the steel tower, and ensuring the assembly accuracy and efficiency of the subsequent three-dimensional assembly of the steel tower segments and the three-dimensional assembly of the steel tower at the assembly site.

[0107] Due to the limited size of the workshop, the length of the workshop may not be able to accommodate the entire length of the pre-assembled middle anchor chamber 3. In this case, the pre-assembly can be carried out in multiple rounds according to the sequence of the steel tower segments. The next round is pre-assembled using the parent beam left over from the previous round as a standard.

[0108] Specifically, process 1 above includes:

[0109] Process 1.1 Construct 3 sets of special splicing frames for the central anchor chamber according to the wall panel line shape, and set longitudinal and transverse baselines and measurement points;

[0110] Procedure 1.2: Hoist the outer anchor plate unit into the leveled assembly jig, align the longitudinal baseline of the anchor plate with the longitudinal baseline of the jig, and after adjustment, mark the assembly system lines of the transverse partition and anchor box 4.

[0111] In process 1.3, assemble anchor box 4 along the line. Carefully check whether the positioning dimensions of anchor box 4 meet the requirements of the process drawings. After confirming that there are no errors, spot weld anchor box 4 and anchor plate to fix them.

[0112] Step 1.4 Assemble the transverse diaphragms along the lines, paying attention to checking the perpendicularity of the transverse diaphragms to the anchor plates. Once correct, spot weld them in place.

[0113] Process 1.5 Assemble the wall panel units on both sides of the line. Pay attention to checking the verticality, box opening size and diagonal difference between the partition, wall panel and anchor plate. After confirming that there are no errors, spot weld to fix them. Weld the welds between the partition and anchor plate, the wall panel and anchor plate and the partition and wall panel in sequence. After the welds pass the non-destructive testing, they are corrected.

[0114] Step 1.6 Install the upper anchor plate unit and mark the upper transverse diaphragm positioning line on it. After checking that its dimensions are correct, weld the weld between the anchor plate and the wall panel. After the weld passes the non-destructive testing, make corrections.

[0115] Specifically, in the assembly process of the middle anchor chamber 3, in process 1.1, a horizontal jig is made according to the ground sample. After the jig is manufactured, it is measured and inspected to ensure that it is a horizontal jig. Then, the jig is erected linearly. In process 1.2, before the anchor plate unit is assembled in the plane, it needs to be widened. When widening the anchor plate, it needs to be turned over, and safety should be taken into account during the turning. In process 1.3, the anchor box 4 at this time only needs to be installed with a "well" structure. The anchor pipe is not installed yet. The anchor pipe is installed after the plane assembly is completed. When positioning and installing the anchor box 4, the anchor point coordinates need to be determined. The anchor point coordinates are converted according to the actual assembly sequence and provided. In the positioning of the anchor box 4, the anchor points also need to be provided. The coordinates of the intersection of the box support plate and the anchor plate; in process 1.4, when the partition is installed, the allowable error between the end partition and the end of the anchor plate shall not exceed 3mm, the error between partitions shall not exceed 2mm (all measured from the reference side), the assembly gap between the partition and the anchor plate shall not exceed 2mm, and the verticality of the partition shall not exceed 1mm; in process 1.5, when installing the transverse wall panels on both sides, if the panel specifications are large and the wall panel unit is overweight, diagonal braces can be set inside the middle anchor chamber 3 to fix the transverse wall panels on both sides, ensuring that the box opening size will not have a large deviation. The diagonal braces are made of steel. When the temporary supports are installed and positioned, the verticality between the anchor plate and the wall panel must first be adjusted. The verticality of the assembly gap between the anchor plate and the wall panel must not exceed 1mm, and the assembly gap must not exceed 2mm. When installing the upper anchor plate in process 1.6, it must be installed from top to bottom. During installation, the upper anchor plate should be lowered slowly to avoid collision with the wall panel, which could alter the box opening size. After installation, the anchor plate and wall panel should be positioned, adjusted, and welded. The diagonal error of the box opening size after welding must not exceed 4mm. If there is a partition on the upper side of the anchor plate, it must be installed first. After the partition is installed and positioned, the reinforcing ribs of the transverse wall panel should be inserted. In process 2, after assembly, the anchor points of anchor box 4 must be reversed to the outside of the transverse wall panels on both sides to prevent subsequent three-dimensional assembly. During the installation process, the anchor points are re-measured and their positions are measured. After assembly, matching parts for planar assembly need to be installed to facilitate quick positioning during final assembly. By using the long-line method for pre-assembly, the matching accuracy requirements between steel tower segments can be met, thus ensuring the linear accuracy of the steel tower during the three-dimensional final assembly. The matching parts are positioned and installed on the wall panels and anchor plates. After the overall planar assembly is completed, the box opening size, the total length of the trial assembly, and the tolerance dimensions such as the twist of the members need to be inspected. The acceptance error is inspected according to the manufacturing inspection rules. In process 3, the beam transport trolley is used for demolding. After demolding, the beam is directly transported to the sand room for sandblasting and coating. After sandblasting and coating are completed, the entire segment is assembled three-dimensionally.

[0116] Optionally, combined Figures 1-15As shown, step S5 specifically includes five rounds of assembly: In the first round of assembly, segment ST1 and segment ST2 are rigidly connected to the support pier. Then, segment ST1 and segment ST2 are used as the parent segments to sequentially assemble segment ST3, segment ST4, and segment ST5. In the second round of assembly, segment ST5 is used as the parent segment to sequentially assemble segment ST6 and segment ST7. In the third round of assembly, segment ST7 is used as the parent segment to sequentially assemble segment ST8 and segment ST9. In the fourth round of assembly, segment ST9 is used as the parent segment to sequentially assemble segment ST10 and segment ST11. In the fifth round of assembly, segment ST11 is used as the parent segment to sequentially assemble segment ST12 and segment ST13.

[0117] Specifically, during the three-dimensional assembly of the steel tower segments, the central anchor chamber 3 is placed on the jig, and its verticality and opening dimensions are measured to confirm that the dimensions are correct. The two side anchor chambers 2 are then installed. After the side anchor chambers 2 are installed, it is necessary to confirm that the relative positions of the side anchor chambers 2 are correct. The installation position of the anchor box 4 needs to be re-measured to prevent any deviation in the position of the anchor box 4. The two side box chambers 1 are then installed, and their opening dimensions, anchor box 4 positioning, and the gap between the wall panels are measured. After confirming that everything is correct, all welds are welded according to the welding process.

[0118] Assemble the second steel tower segment sequentially according to the above steps, paying attention to the assembly gap and verticality between the two segments. After adjustment, fix the segments in place. After adjusting the dimensions, measure the spatial angle of each anchor point on the anchor plate and the spatial position of the centroid of the cable guide outlet; ensure the error is within the allowable range. Install the matching components between segments. Referring to the previous steps, assemble the next steel tower segment into blocks, using the reference end as a benchmark, adjusting the port spacing to align the ports. After adjusting all dimensions of the third segment, install the matching components between the components within the segment. Re-measure the spacing between adjacent anchor points on the anchor plates of the two segments and the spacing of the cable guide outlet. After adjusting all dimensions, weld the temporary matching components between the two segments. Allow for shrinkage allowance at the butt weld joint between the matching components. Disassemble the non-parent segment, remove it from the jig, move the parent segment to the head of the jig, and continue assembling the next round of steel towers using the parent segment as a benchmark.

[0119] During the three-dimensional assembly of the steel tower, segments ST1 and ST2 act as legs. The closure section of the steel tower needs to be assembled with both legs in the first round of assembly. Before assembly, the centerline positions of segments ST1 and ST2 of the two legs should be determined. Then, segments ST3 and ST4 of the upper closure section should be assembled sequentially from left to right or from right to left. When assembling the closure section of the steel tower, it is important to ensure that segments ST1 and ST2 are at the same level and that their inclination angles meet the requirements of the drawings. Otherwise, it will affect the horizontal height and joint of segments ST3 and ST4 of the upper section, causing misalignment between segments ST3 and ST4.

[0120] It should be noted that the requirements for the three-dimensional assembly of the steel tower are as follows: the segmental assembly and pre-assembly should be completed in one go on the same jig, and the assembly and matching should be carried out in a step-by-step manner.

[0121] ① Strictly follow the longitudinal and transverse baselines set on the jig to lay out the first section of the steel tower. The steel tower section is rigidly connected to the support pier (serving as a fixed support).

[0122] ② Assemble the remaining beam segments in sequence. Using the fixed measurement reference point of the jig as the base point, use a laser theodolite to measure the longitudinal baseline of the beam segment, so that the center line of the bridge axis is within the allowable deviation range, and the axis of each segment is within the allowable deviation range from the previous segment.

[0123] ③ Based on the spacing of the steel tower baseline, mark the allowance lines for the segments and cut the bevels.

[0124] ④ After all points have passed inspection, the steel tower matching parts are assembled and welded.

[0125] ⑤ According to the process flow, the pre-assembly of steel tower segments must be carried out after the overall inspection of the segments is completed, and the segments must be in a free state before pre-assembly.

[0126] Specifically, the overall assembly process of the steel tower and the design of the assembly jig should meet the following requirements:

[0127] ① Trial assembly should be carried out on a leveled jig. The jig foundation must have sufficient load-bearing capacity to ensure that no settlement occurs during use. The jig must have sufficient rigidity to prevent deformation during use.

[0128] ② Set longitudinal and transverse baselines and reference points on the jig to control the position and height of the steel tower segments and ensure the dimensions of each part. Set independent baselines and reference points outside the jig to facilitate inspection of the jig at any time.

[0129] ③ The jig should meet the requirements of convenient and safe entry and exit of the beam transport trolley.

[0130] ④ After each batch of steel tower segments is removed from the jig, the jig frame should be re-inspected, and inspection records should be made. Only after it is confirmed to be qualified can the next round of assembly be carried out.

[0131] A construction process for a cable-stayed bridge, using the steel tower manufacturing process described above.

[0132] A steel tower manufactured using the steel tower manufacturing process described above.

[0133] It should be noted that the steel tower in this application is a steel tower with a continuously changing cross-section. The cross-section of the steel tower segments gradually decreases from bottom to top. Therefore, in the areas of the steel tower segments with changing cross-sections, different manufacturing processes need to be developed according to the actual situation. When the steel tower segments are slowly closed by the inclined wall panels, different manufacturing schemes are adopted according to the different roles played by the inclined wall panels in different segments.

[0134] When the inclined wall panel is in the side anchor chamber 2, the inclined wall panel needs to be installed first because it needs to bear the function of the outer wall panel. In addition, the lifting lugs for hoisting need to be welded to the inclined wall panel. Therefore, it must be installed first.

[0135] When the inclined wall panels are joined, the anchor pipe needs to pass through the joint between the two inclined wall panels. At this time, the inclined wall panels cannot be installed first, as this would cause inaccurate alignment between the middle anchor chamber 3 and the side anchor chamber 2 during the three-dimensional assembly. Therefore, the inclined wall panels need to be installed during the three-dimensional assembly. This is because installation during the three-dimensional assembly will not affect the alignment between the side anchor chamber 2 and the middle anchor chamber 3, and it is also beneficial to adjust the overall shape of the steel tower. Furthermore, when installed during the assembly, the main weld of this inclined wall panel is a vertical weld, and there is no overhead weld, which is also beneficial to the operation during welding.

[0136] The steel-concrete composite section of the steel tower adopts a structure with upper and lower sides. From the top of the pressure plate, the interior of the box chamber does not require concrete pouring, but the interior of the box chamber below the pressure plate does. This presents certain installation challenges for the on-site positioning and installation of the steel-concrete composite section. Firstly, the installation accuracy of the steel-concrete composite section itself must be guaranteed, as the manufacturing precision of the concrete part cannot match that of the steel tower. Therefore, this necessitates testing the precision of the steel-concrete composite section during installation and the adjustment devices. Secondly, ensuring that the steel-concrete composite section does not shift after concrete pouring is another important issue in its installation. Therefore, a specific installation method for the steel-concrete composite section needs to be developed. The process involves several steps. First, during the installation of the steel-concrete composite section, a stiffening frame needs to be installed below the bearing plate. This stiffening frame is constructed using steel pipe piles. After installation, jack adjustment points need to be set on the stiffening frame. Once the steel tower segments are placed on the stiffening frame, they are leveled using jacks. After leveling, a positioning truss is used to connect the left and right steel-concrete composite sections. Before installing the positioning truss, the elevation and alignment between the left and right segments need to be measured and adjusted. Once the elevation and alignment of the two segments meet the requirements, the positioning truss is installed. The positioning truss effectively controls errors caused by concrete pouring in the steel-concrete composite sections. A polytetrafluoroethylene (PTFE) shim is added at the connection between the stiffening frame and the bearing plate to increase the sliding of the steel tower segments during adjustment.

[0137] A cable-stayed bridge is manufactured using the steel tower manufacturing process described above, and / or using the cable-stayed bridge construction process described above, and / or includes the steel towers described above.

[0138] While the disclosure is as stated above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of this disclosure, and all such changes and modifications will fall within the protection scope of this invention.

Claims

1. A steel tower manufacturing process, characterized in that, include: S1. Divide the steel tower into multiple steel tower segments, and divide each steel tower segment into blocks. After the blocks are divided, each steel tower segment includes all or part of the four boxes: side box chamber (1), side anchor chamber (2), middle anchor chamber (3), and anchor box (4). Box assembly: S2. The side box chamber (1), the side anchor chamber (2), the middle anchor chamber (3) and the anchor box (4) are assembled separately using the long line method; Container transfer: S3. Transfer the assembled side box chamber (1), side anchor chamber (2), middle anchor chamber (3) and anchor box (4) to the final assembly site; Three-dimensional assembly of steel tower segments: S4. Install the side anchor chambers (2) on both sides of the central anchor chamber (3), and install the side box chamber (1) on the side of the side anchor chamber (2) away from the central anchor chamber (3); Steel tower three-dimensional assembly: S5. The steel tower segments are assembled sequentially from bottom to top using a hoisting method; The assembly process of the side chamber (1) includes: Process 1. The side chamber (1) on the steel tower segment is manufactured on a special jig; Process 2. The multiple side chambers (1) are pre-assembled using the long-line method according to the assembly sequence of the steel tower segments, and the specific pre-assembly round is determined according to the size of the workshop site; Process 3. After each round of pre-assembly is completed, the side box chamber (1) is disassembled. After disassembly, the last section of the side box chamber (1) is left as the mother beam to participate in the next round of assembly. The remaining side box chambers (1) are disassembled and transported to the general assembly site for three-dimensional assembly of steel tower segments. The assembly process of the side anchor chamber (2) includes: Process 1. The side anchor chamber (2) on the steel tower segment is manufactured on a special jig, and the anchor box (4) is assembled on the side anchor chamber (2); Process 2. The multiple side anchor chambers (2) are pre-assembled using the long-line method according to the assembly sequence of the steel tower segments, and the specific pre-assembly round is determined according to the size of the workshop site; Process 3. After each round of pre-assembly is completed, the side anchor chamber (2) is disassembled. After disassembly, the last section of the side anchor chamber (2) is left as the mother beam to participate in the next round of assembly. The remaining side anchor chambers (2) are disassembled and transported to the general assembly site for three-dimensional assembly of steel tower segments. The assembly process of the middle anchor chamber (3) includes: Process 1. The middle anchor chamber (3) on the steel tower segment is manufactured on a special jig, and the anchor box (4) is assembled on the middle anchor chamber (3); Process 2. The multiple anchor chambers (3) are pre-assembled using the long-line method according to the assembly sequence of the steel tower segments. The specific pre-assembly round is determined according to the size of the workshop site. Process 3. After each round of pre-assembly is completed, the middle anchor chamber (3) is disassembled. After disassembly, the last section of the middle anchor chamber (3) is left as the mother beam to participate in the next round of assembly. The remaining middle anchor chambers (3) are disassembled and transported to the general assembly site for three-dimensional assembly of steel tower segments.

2. The steel tower manufacturing process according to claim 1, characterized in that, The steel tower segments include standard segments and non-standard segments. The standard segments include segment 3 (ST3), segment 4 (ST4), segment 5 (ST5), segment 6 (ST6), segment 7 (ST7), segment 8 (ST8), segment 9 (ST9), and segment 10 (ST10). The non-standard segments include segment 1 (ST1), segment 2 (ST2), segment 11 (ST11), segment 12 (ST12), and segment 13 (ST13).

3. The steel tower manufacturing process according to claim 2, characterized in that, Step S5 specifically includes five rounds of assembly: In the first round of assembly, segment 1 (ST1) and segment 2 (ST2) are rigidly connected to the support pier. Then, segment 1 (ST1) and segment 2 (ST2) are used as the parent segments to sequentially assemble segment 3 (ST3), segment 4 (ST4), and segment 5 (ST5). In the second round of assembly, segment 5 (ST5) is used as the parent segment to sequentially assemble segment 6 (ST6) and... Segment 7 (ST7); Third round of assembly, using segment 7 (ST7) as the parent segment, sequentially assembling segment 8 (ST8) and segment 9 (ST9); Fourth round of assembly, using segment 9 (ST9) as the parent segment, sequentially assembling segment 10 (ST10) and segment 11 (ST11); Fifth round of assembly, using segment 11 (ST11) as the parent segment, sequentially assembling segment 12 (ST12) and segment 13 (ST13).

4. The steel tower manufacturing process according to claim 3, characterized in that, In the first round During the final assembly, first locate the center line positions of the first segment (ST1) and the second segment (ST2), and then assemble the third segment (ST3) and the fourth segment (ST4) sequentially from left to right or from right to left.

5. A construction process for a cable-stayed bridge, using the steel tower manufacturing process as described in any one of claims 1 to 4.

6. A steel tower manufactured using the steel tower manufacturing process as described in any one of claims 1 to 4.

7. A cable-stayed bridge manufactured using the steel tower manufacturing process as described in any one of claims 1 to 4, and / or using the cable-stayed bridge construction process as described in claim 5, and / or including the steel tower as described in claim 6.

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