A cast-in-situ antique concrete corbel arch construction method

Abstract

The present application relates to a kind of cast-in-situ antique concrete corbel construction method, according to drawing calculation, the structure and quantity of keel, special-shaped steel, connecting rod needed are used;Prepare the keel, special-shaped steel and connecting rod needed;Special-shaped steel, keel, value steel, form corbel inner frame between them;The outside of corbel inner frame is wrapped with wire mesh, and the top of corbel inner frame is not blocked by wire mesh;Coated with mortar outside wire mesh, after the molding of mortar, get mortar formwork;Pour concrete in the molded mortar formwork, and the concrete is carved according to the shape of corbel, continue to carry out water conservation during the period, after complete solidification, final acceptance is carried out;The pouring mode of traditional wooden formwork is abandoned, the keel is used to build corbel sketch with special-shaped steel, effectively avoid the problems of difficult formwork preparation, difficult reinforcement, unfirm reinforcement, formwork splicing and supporting deviation.

Description

Technical Field

[0001] This invention relates to a construction method for cast-in-place antique-style concrete bracket sets, belonging to the field of building construction technology. Background Technology

[0002] Dougong, also known as Dougong, Douke, Puzuo, etc., is a unique structure in Chinese architecture. Dougong has a very long history of origin and development. The earliest example of Dougong can be found in the bronze table with four dragons and four phoenixes unearthed from the Zhongshan State during the Warring States period. With people's pursuit of the beauty of the interior and exterior of buildings, Dougong has become a major feature of modern buildings.

[0003] Traditionally, concrete bracket sets are constructed using prefabricated wooden templates, which are then poured into the concrete. However, due to the complex structure of the bracket sets, their high curvature, and the prevalence of irregular shapes, this traditional method of casting bracket sets using template splicing presents several problems. These include difficulties in reinforcement, unreliable reinforcement, and deviations caused by template splicing and support. Consequently, the finished concrete bracket sets often exhibit issues such as misalignment and uneven surfaces.

[0004] For example, CN111719780A describes a construction process for cast-in-place concrete brackets in antique-style buildings. This process makes it easier to install the brackets by prefabricating the bracket components in advance. Compared with the traditional method of pouring the entire structure after completion, this construction process is more convenient and faster.

[0005] However, because the shapes of the brackets are different for different buildings, the prepared templates cannot be reused, resulting in a serious waste of resources. Summary of the Invention

[0006] The purpose of this invention is to provide a construction method for cast-in-place antique-style concrete bracket sets to solve the problems mentioned in the background art.

[0007] The technical solution of the present invention is as follows:

[0008] A construction method for cast-in-place antique-style concrete bracket sets includes the following steps:

[0009] Step 1: Based on the characteristics of the building, analyze and prepare the shape of the bracket set structure, and draw up the drawings;

[0010] Step 2: Calculate the structure and quantity of the required keel, special-shaped steel bars, and connecting bars based on the drawings;

[0011] Step 3: Prepare the required keel, irregular-shaped steel bars, and connecting bars;

[0012] Step 4: Fix the keel to the pre-embedded rebar in the building, fix the irregular rebar to the corresponding position of the keel, and tie the connecting bar between the irregular rebar, keel and rebar to form the inner frame of the bracket.

[0013] Step Five: Wrap the outer side of the inner frame of the bracket with wire mesh, and ensure that there is no wire mesh blocking at the top of the inner frame of the bracket;

[0014] Step Six: Coat the outside of the wire mesh with mortar, and after the mortar is formed, a mortar template is obtained;

[0015] Step Seven: Pour concrete into the formed mortar template, and刻画 the concrete according to the shape of the bracket. During this period, continuous water replenishment and maintenance are carried out, and final acceptance is carried out after complete solidification.

[0016] Preferably, the connecting bars include a first connecting bar and a second connecting bar; the keel is a C14 steel bar, and the special-shaped steel bar is a C6 steel bar; A4 grade foam concrete is used during pouring, and the pouring method is carried out in batches.

[0017] Preferably, in Step Four, before welding, the special-shaped steel bars are tied and fixed to the keel, the special-shaped steel bars to the special-shaped steel bars, and the keel to the implanted steel bars through binding wires;

[0018] In Step Four, after the inner frame of the bracket is formed, a primary acceptance is carried out. The acceptance contents include size measurement, stability test, steel bar quality inspection, and firmness inspection of the welding position.

[0019] Preferably, in Step Five, the wire mesh wraps the outer side of the inner frame of the bracket in a "匚" shape with the opening facing upwards.

[0020] Preferably, in Step Six, after the mortar template is obtained after the mortar is formed, the mortar template is regularly water-replenished and maintained. After the mortar template is dried and solidified, a secondary acceptance is carried out. The acceptance contents include measuring the size, shape accuracy, cracks, and depressions, and timely repair and treatment are carried out.

[0021] Preferably, in Step Seven, the final acceptance contents include measuring the size, shape accuracy, cracks, and depressions, and timely repair and treatment are carried out.

[0022] Preferably, the required keel, special-shaped steel bars, first connecting bars, and second connecting bars are prepared by a bending arc mechanism and a steel bar cutting machine;

[0023] The bending arc mechanism includes a base, and a plurality of support disks circumferentially distributed around the base, and a variable diameter structure installed on the support disks. The support disks are driven by corresponding oil cylinders to approach or move away from the center of the base.

[0024] Preferably, the variable diameter structure includes a stud, and a plurality of adjusting arc blocks circumferentially distributed around the stud. The adjusting arc blocks slide on the support disks to approach or move away from the stud. A screw sleeve is threadedly connected to the stud, and the screw sleeve and the adjusting arc blocks are connected by corresponding connecting rods.

[0025] Preferably, it also includes a fixed plate, a lifting device, and a pressure member at the output end of the lifting device. The fixed plate is provided with multiple sets of shaping rods. The shaping rods are driven to reset by corresponding elastic elements. The lifting device pushes the shaping rods closer to the base through the pressure member.

[0026] Preferably, the side wall of the pressing component is provided with a plurality of receiving grooves, and a shaping component is detachably installed in the receiving groove. Each group of shaping components has shaping grooves with different structures on its side wall, and the lowermost group of shaping grooves is used to cooperate with the shaping rod.

[0027] The present invention has the following beneficial effects:

[0028] The traditional wooden formwork casting method was abandoned. Instead, a keel and irregularly shaped steel bars were used to build the prototype of the dougong (bracket set). This effectively avoided the problems of difficult formwork preparation, difficult reinforcement, unreliable reinforcement, and deviation caused by formwork splicing and support. Furthermore, the mortar formwork is part of the supporting antique-style concrete dougong, avoiding the waste caused by the inability to reuse the mortar formwork. Attached Figure Description

[0029] Figure 1 This is a flowchart of the present invention;

[0030] Figure 2 This is a schematic diagram of the bracket structure of the present invention;

[0031] Figure 3 For the present invention Figure 2 Enlarged view of point A in the middle;

[0032] Figure 4 For the present invention Figure 2 Main view;

[0033] Figure 5 This is a schematic diagram of the bending mechanism structure of the present invention;

[0034] Figure 6 This is a schematic diagram of the support disk and its mating components of the present invention;

[0035] Figure 7 This is a schematic diagram of the assembly structure of the lifting device, pressure component, and shaping plate of the present invention.

[0036] Figure 8 This is a schematic diagram of the fixing plate structure of the present invention;

[0037] Figure 9 This is a schematic diagram of the inverted structure of the shaping plate of the present invention.

[0038] The reference numerals in the figure are as follows:

[0039] 1. Rebar; 2. Keel; 3. Irregularly shaped rebar; 4. First connecting bar; 5. Binding wire; 6. Second connecting bar; 7. Bending mechanism; 8. Base; 9. Support seat; 10. Slide groove; 11. Support plate; 12. Sliding block; 13. Adjusting groove; 14. Adjusting arc block; 15. Arc groove; 16. First shaft seat; 17. Stud; 18. Screw sleeve; 19. Second shaft seat; 20. Connecting rod; 21. Locking nut; 22. Hydraulic cylinder; 23. Lifting device; 24. Pressing component; 241. Receiving groove; 25. Shaping plate; 251. Shaping groove; 26. Fixing plate; 261. Shaping rod; 262. Elastic component. Detailed Implementation

[0040] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0041] Example:

[0042] like Figure 1-6 As shown:

[0043] Step 1: Structural diagram analysis. Based on the characteristics of the building, the shape of the bracket structure is prepared, and then a sketch is drawn using CAD drawing software.

[0044] Step 2: CAD sketch analysis. Analyze the drawn sketch to identify the required components: 2 keel bars, 3 irregular steel bars, 4 first connecting bars, and 6 second connecting bars.

[0045] Step 3: Positioning and laying out the steel reinforcement cage. Based on the sketch analysis, the approximate size, quantity, and shape of the keel 2, irregular steel bar 3, first connecting bar 4, and second connecting bar 6 are obtained. Then, the bending mechanism is used in conjunction with an external steel bar cutting machine to prepare the required keel 2, irregular steel bar 3, first connecting bar 4, and second connecting bar 6.

[0046] Step 4: Steel bar cutting and processing. The prepared keel 2 is fixed to the pre-embedded rebar 1 in the building with binding wire 5. Then, the corresponding irregular steel bars 3 are fixed to the keel 2 with binding wire 5. Two adjacent irregular steel bars 3 are also connected with binding wire 5 to form the general shape of the entire bracket. The first connecting bar 4 and the second connecting bar 6 are tied between the irregular steel bars 3, the keel 2 and the rebar 1 in sequence. Then, welding equipment is used to weld and reinforce the rebar 1, the keel 2, the irregular steel bars 3, the first connecting bar 4 and the second connecting bar 6 to prepare the entire inner frame of the bracket.

[0047] Step 5: Initial Acceptance Inspection. The prepared bracket set will undergo an initial acceptance inspection, which will include dimensional measurement, stability testing, steel reinforcement quality inspection, and welding position firmness inspection.

[0048] Step 6: Cover and reinforce with wire mesh. Wrap the wire mesh around the outer side of the prepared inner frame of the bracket set. The wire mesh is connected and reinforced to the keel 2 or the profiled steel bar 3 through the binding wire 5. The wire mesh is wrapped in a "匚" shape with the opening facing upwards, so that there is no wire mesh blocking at the top of the inner frame of the bracket set.

[0049] Step 7: Form the mortar template. Cover the wire mesh with mortar. After the mortar is formed, the mortar template is obtained. Regularly replenish water for maintenance of the mortar template. After the mortar template is dried and solidified, conduct a secondary inspection. The inspection contents include measuring dimensions, shape accuracy, cracks, and depressions, and repair and process them in a timely manner.

[0050] Step 8: Pour. Pour concrete into the formed mortar template and刻画 the concrete according to the shape of the bracket set. During this period, continuously replenish water for maintenance. After it is completely solidified, conduct a final inspection. The inspection contents include measuring dimensions, shape accuracy, cracks, and depressions, and repair and process them in a timely manner.

[0051] In this embodiment, in Step 3, the keel 2 is a C14 steel bar, and the profiled steel bar 3 is a C6 steel bar.

[0052] In this embodiment, in Step 3, the arc bending mechanism includes a base 8. Three support seats 9 are installed on the outer side of the base 8. An oil cylinder 22 is installed on the upper part of each support seat 9. Three chutes 10 are opened on the upper surface of the base 8. A support disc 11 is provided on the upper part of each chute 10. A slider 12 matching the chute 10 is fixedly connected to the bottom of the support disc 11. The output shaft of the oil cylinder 22 is fixedly connected to the slider 12.

[0053] Six adjusting grooves 13 are opened on the upper surface of the support disc 11. An adjusting arc block 14 is slidably connected to the upper part of each adjusting groove 13. An arc groove 15 is opened at the center position on the outer side of the adjusting arc block 14. A first shaft seat 16 is installed on the inner side wall of the adjusting arc block 14. A stud 17 is rotatably installed at the center position on the upper part of the support disc 11. A screw sleeve 18 is threadedly connected to the outside of the stud 17. A second shaft seat 19 is fixedly installed on the outside of the screw sleeve 18. A connecting rod 20 is rotatably connected between the second shaft seat 19 and the first shaft seat 16.

[0054] An internal hexagonal groove is opened on the top surface of the stud 17. A locking nut 21 is threadedly connected to the outside of the stud 17 at a position above the screw sleeve 18.

[0055] When preparing the irregularly shaped steel bar 3, firstly, based on the shape and size of the irregularly shaped steel bar 3 to be prepared, adjust the coverage area of ​​the six adjusting arc blocks 14, thereby adjusting the size of the bending wheel composed of the six sets of adjusting arc blocks 14. During operation, insert an external hex wrench into the internal hexagonal slot, and then rotate the stud 17. The stud 17 moves vertically through the thread between it and the threaded sleeve 18, thereby driving the six second bearing seats 19 to move vertically. The six second bearing seats 19, through the six first bearing seats 16 and the connecting rod 20, drive the six adjusting arc blocks 14 in the adjusting groove 13. After sliding the inner side of the sleeve 18 and adjusting it to a suitable position, rotate the locking nut 21 to press it against the upper part of the sleeve 18. Adjust the adjusting arc blocks 14 on the upper part of the three support plates 11 according to the same method. After adjustment, place the irregular steel bar 3, the first connecting bar 4 or the second connecting bar 6 that needs to be bent into the arc between the adjacent adjusting arc blocks 14 of the three support plates 11. Then start at least one of the hydraulic cylinders 22 to work. The hydraulic cylinder 22 pushes the support plate 11 to slide in the slide groove 10, thereby bending the irregular steel bar 3, the first connecting bar 4 or the second connecting bar 6.

[0056] Since the position of each adjusting arc block 14 is adjustable, the size of the bending wheel composed of six adjusting arc blocks 14 can be adjusted, which facilitates the bending of steel bars with different curvature and position bending requirements, effectively increasing the convenience of processing irregular steel bars 3, first connecting bars 4 and second connecting bars 6.

[0057] In this embodiment, in step six, when covering with wire mesh, the overlap length between two adjacent wire meshes is 80-100cm, and the wire mesh is galvanized wire mesh.

[0058] An overlap of 80-100cm can effectively prevent adjacent wire meshes from separating, thereby reducing the occurrence of cracks in the mortar formwork.

[0059] In this embodiment, in step seven, the steel wire mesh is covered with M5 mortar, and the covering thickness is 40mm.

[0060] In this embodiment, in step eight, A4 grade foamed concrete with a dry density ρ of 400 kg / m³ is used during pouring. 3 The pouring method adopts a multi-stage pouring method.

[0061] Foamed concrete is lighter, reducing the weight of the brackets and increasing the stability of the brackets and the building. The method of pouring in stages can avoid the leakage of grout that occurs when pouring in one go.

[0062] Example 2: Includes all the content of Example 1:

[0063] like Figure 7-9 As shown:

[0064] The lifting device 23 can be vertically fixed with telescopic cylinders and fixed with fixed plates 26. The downward output end of the lifting device 23 is equipped with a pressure member 24. The side wall of the pressure member 24 is provided with a receiving groove 241. The receiving groove 241 is adapted to the shape of the shaping plate 25. The shaping plate 25 is embedded in one set of receiving grooves 241 and fixed with screws. The bottom wall of the shaping plate 25 is provided with a shaping groove 251. The shaping grooves 251 of each set of shaping plates 25 are different.

[0065] Multiple shaping rods 261 are linearly slidably connected to the fixed plate 26. The moving direction of the shaping rods 261 is consistent with the extension and retraction direction of the lifting device 23. An elastic element 262 is connected between the shaping rods 261 and the fixed plate 26. The elastic force of the elastic element 262 pushes the corresponding shaping rods 261 to move upward.

[0066] When the bending mechanism bends the reinforcing bar 1, keel 2, irregular reinforcing bar 3, first connecting bar 4, and second connecting bar 6, in order to improve the bending accuracy, the lifting device 23 drives the vertical pressure member 24 to descend, so that the shaping groove 251 of the bottom shaping plate 25 abuts against multiple sets of shaping rods 261. The shaping groove 251 of the shaping plate 25 pushes some of the shaping rods 261 to descend vertically and approach the base 8. The descended shaping rods 261 are used to restrict the bending of the reinforcing bar 1 / keel 2 / irregular reinforcing bar 3 / first connecting bar 4 / second connecting bar 6, thereby improving the bending accuracy.

[0067] The lifting device 23 raises and resets, causing the pressure member 24 to rise and reset vertically, so that the shaping groove 251 of the lowest shaping plate 25 is separated from the multiple shaping rods 261. Under the push of the elastic force of the elastic member 262, the corresponding shaping rods 261 rise vertically and reset and move away from the base 8.

[0068] When bending and installing rebar 1 / keel 2 / irregular rebar 3 / first connecting bar 4 / second connecting bar 6, select the corresponding shaping plate 25 and place it in the bottommost receiving groove 241.

[0069] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A construction method for cast-in-place antique-style concrete bracket sets, characterized in that, It includes the following steps: Step 1: Analyze the characteristics of the building to prepare the shape of the bracket structure and draw the drawings; Step 2: Calculate the structure and quantity of the keel (2), special-shaped steel bars (3), and connecting bars required according to the drawings; Step 3: Prepare the required keel (2), special-shaped steel bars (3), and connecting bars; Step 4: Fix the keel (2) to the implanted bars (1) embedded in the building, fix the special-shaped steel bars (3) at the corresponding positions of the keel (2), and bind the connecting bars between the special-shaped steel bars (3), keel (2), and implanted bars (1) to form the inner frame of the bracket; Step 5: Wrap the outside of the inner frame of the bracket with a wire mesh, and make sure there is no wire mesh blocking at the top of the inner frame of the bracket; Step 6: Coat the outside of the wire mesh with mortar, and obtain a mortar template after the mortar is formed; Step 7: Pour concrete into the formed mortar template, and刻画 the concrete according to the shape of the bracket. During this period, continuously carry out water replenishment maintenance. After it is completely solidified, conduct a final acceptance; The connecting bars include the first connecting bar (4) and the second connecting bar (6); Prepare the required keel (2), special-shaped steel bars (3), first connecting bar (4), and second connecting bar (6) through a bending arc mechanism and a steel bar cutting machine; The bending arc mechanism includes a base (8), and a number of support discs (11) circumferentially distributed around the base (8), and a variable diameter structure installed on the support discs (11). The support discs (11) are driven by corresponding oil cylinders (22) to approach or move away from the center of the base (8).

2. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 1, characterized in that: The keel (2) is a C14 steel bar, and the special-shaped steel bar (3) is a C6 steel bar; Foamed concrete is used during pouring, and the pouring method is divided into multiple pourings.

3. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 1, characterized in that: In Step 4, before welding, bind and fix the special-shaped steel bar (3) to the keel (2), the special-shaped steel bar (3) to the special-shaped steel bar (3), and the keel (2) to the implanted bar (1) with binding wires (5); In Step 4, conduct a primary acceptance after forming the inner frame of the bracket. The acceptance content includes dimension measurement, stability test, steel bar quality inspection, and welding position firmness inspection.

4. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 1, characterized in that: In Step 5, the wire mesh wraps the outside of the inner frame of the bracket in a "匚" shape with the opening facing up.

5. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 1, characterized in that: In Step 6, after obtaining the mortar template after the mortar is formed, conduct regular water replenishment maintenance on the mortar template. After the mortar template is dried and solidified, conduct a secondary acceptance. The acceptance content includes measuring dimensions, shape accuracy, cracks, and depressions, and repair and treatment in a timely manner.

6. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 1, characterized in that: In Step 7, the final acceptance content includes measuring dimensions, shape accuracy, cracks, and depressions, and repair and treatment in a timely manner.

7. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 1, characterized in that: The variable diameter structure includes a stud (17) and a number of adjusting arc blocks (14) circumferentially distributed around the stud (17). The adjusting arc blocks (14) slide on the support disc (11) to approach or move away from the stud (17). A stud sleeve (18) is threadedly connected to the stud (17), and the stud sleeve (18) and the adjusting arc block (14) are connected by corresponding connecting rods (20).

8. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 7, characterized in that: It also includes a fixed plate (26), a lifting device (23) and a pressure member (24) at the output end of the lifting device (23). The fixed plate (26) is provided with multiple sets of shaping rods (261). The shaping rods (261) are driven to reset by the corresponding elastic members (262). The lifting device (23) pushes the shaping rods (261) close to the base (8) through the pressure member (24).

9. The construction method for cast-in-place antique-style concrete bracket sets as described in claim 8, characterized in that: The side wall of the pressing component (24) is provided with several receiving grooves (241). A shaping component (25) is detachably installed in the receiving groove (241). Each set of shaping components (25) has a shaping groove (251) with a different structure on its side wall. The bottom set of shaping grooves (251) is used to cooperate with the shaping rod (261).

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