A segmented modular pouring method for an ultra-deep large-volume unloading pit

Abstract

The application provides a segmented modular pouring method for an ultra-deep large-volume unloading pit, which comprises the following steps in sequence: measurement, positioning, and line laying; base trench excavation; cushion construction; brick wall masonry; waterproof roll construction; pile cap construction; column, wall plate, and stairwell construction; pre-embedded steel column construction; hydraulic flap foundation and top plate pouring; ramp excavation and cushion pouring; ramp brick wall masonry; ramp waterproof roll construction; ramp pile cap construction; ramp wall plate and top plate construction; ground pouring; and completion acceptance. The application optimizes the "concrete layered pouring method", solves the high-difficulty work of layered pouring of the main body of the ultra-deep large-volume unloading pit, reduces the workload, improves the work efficiency, reasonably optimizes the template expansion prevention and reinforcement measures, improves the work efficiency, saves the construction cost, adopts the 9.4° large-gradient grain conveying ramp segmented interval pouring technology, effectively solves the difficulty of ramp concrete molding, and effectively solves the cooling during the large-volume concrete pouring process and the post-pouring maintenance work.

Description

Technical Field

[0001] This invention relates to the field of concrete construction technology, specifically to a segmented modular pouring method for ultra-deep, large-volume grain unloading pits. Background Technology

[0002] The main factors affecting the construction quality of ultra-deep, large-volume grain unloading pit concrete include engineering construction technology, concrete pouring and vibration, and concrete temperature control. Therefore, construction workers need to fully understand the characteristics and related technologies of ultra-deep, large-volume concrete construction and use reasonable methods to solve concrete construction problems. Summary of the Invention

[0003] To address the aforementioned problems, this invention discloses a segmented modular casting method for ultra-deep, large-volume grain unloading pits.

[0004] The specific plan is as follows:

[0005] A segmented modular casting method for ultra-deep, large-volume grain unloading pits, characterized by the following steps in sequence: measurement, positioning, and layout; foundation trench excavation; subgrade construction; brick wall masonry; waterproof membrane construction; foundation construction; column, wall panel, and stairwell construction; pre-embedded steel column construction; hydraulic tilting foundation and top slab casting; ramp excavation and subgrade casting; ramp brick wall masonry; ramp waterproof membrane construction; ramp foundation construction; ramp wall panel and top slab construction; ground casting; and final acceptance.

[0006] As a further improvement of the present invention, it includes deep foundation pit earthwork construction, which includes the following steps:

[0007] S1. Prepare a special construction plan for deep foundation pits and strictly implement the special construction plan after verification;

[0008] S2. Surveying and Setting Out: Before earthwork excavation, after surveying, positioning, and providing elevations, the upper and lower edges of the excavation site, as well as leveling marks, are set out based on the survey results. This allows for real-time control of the excavation dimensions and elevation during excavation, preventing deviations and over-excavation. After verifying the accuracy of the marked lines based on the axis and elevation, site leveling and excavation are carried out. Once earthwork excavation is complete, the foundation pad is positioned, and the pad soil is manually excavated. All on-site personnel must maintain the survey control points and must not damage them arbitrarily. If a control point is damaged or impacted, the site management personnel should be notified immediately, and its coordinates and elevation should be remeasured.

[0009] S3. Construction of the water-retaining sill and erection of guardrails around the foundation pit; the construction of the water-retaining sill shall be carried out in accordance with the special design plan to prevent rainwater from entering the foundation pit; the water-retaining sill shall be 500mm high, 200mm wide at the top, and 2.0m from the center of the excavation edge of the foundation pit; the site around the foundation pit shall be leveled, and a protective fence shall be erected before excavation. The fence shall consist of two horizontal bars and vertical bars, with a height of not less than 1.20m, a lower bar height of 0.6m from the ground, an upper bar height of 1.2m from the ground, a vertical bar spacing of 2m, and a vertical bar distance of 1.5m from the slope edge. The steel pipes used as guardrails shall be painted with alternating red and white warning colors, safety signs shall be hung on the guardrails, and the area shall be enclosed with dense mesh netting.

[0010] S4. Earthwork excavation shall follow the principle of "layered excavation and strict prohibition of over-excavation". It is forbidden to excavate randomly, over-excavate or under-excavate. It is strictly forbidden to dig holes to extract soil. Furthermore, it is forbidden to cause slope instability or collapse due to improper excavation methods.

[0011] When excavating in layers, the depth of each layer shall not exceed 1.5 meters. Excavation shall proceed sequentially from one side, from shallow to deep, and from far to near. The first 300mm above the foundation shall be excavated manually. The last excavation shall be strictly controlled. A level shall be used to control the foundation elevation during excavation, and lime dots shall be sprinkled on the ground to prevent over-excavation. During the excavation process, the foundation pit and the surrounding environment shall be monitored according to the established monitoring plan to provide feedback to guide the construction.

[0012] Drainage ditches and sump pits are constructed at the bottom of the pit for open drainage and dewatering. The sump pits are 0.6m long × 0.6m wide × 0.8m deep and are located at the corner. The drainage ditches have a cross-sectional dimension of 300mm*300mm and slope towards the sump pits. Each sump pit is equipped with a 4-inch sewage pump. The sewage pumps are monitored by designated personnel to promptly pump out the water accumulated in the pits and keep the entire foundation pit dry. The pumped water is discharged to the ditch on the west side through a water hose. To prevent the drainage ditches and sump pits from collapsing, single bricks are laid after the drainage ditches and sump pits are formed, and the surface is coated with 20mm thick waterproof mortar.

[0013] To facilitate workers' access to and from the foundation pit, construction ladders were installed at appropriate locations. The ladders were constructed using Ф48.3 steel pipes, with a width of 1.2 meters. 50mm thick wooden scaffolding boards were laid at the bottom of the platform and inclined runway. Wooden formwork was installed on the inclined runway, with steps 250mm wide and 180mm high. Uprights were inserted into the slope to a depth of at least 500mm. To ensure the stability of the construction access frame, the uprights could be spaced further apart.

[0014] In this embodiment, the foundation construction includes: backfilling and compacting soil, compacting 300mm thick graded crushed stone, and pouring a 200mm thick C20 concrete cushion layer. The concrete used is pumped commercial concrete. After the cushion layer is poured, protective brick walls are built around it. Waterproofing layer laying: the base layer is treated to ensure that it is solid, flat, free of hollow areas, cracks, and water ingress. Detailed nodes are also reinforced. Potholes and damage to the base layer are repaired and leveled with cement mortar. Apply a waterproof coating to the base surface to enhance the adhesion between the base surface and the waterproof membrane; lay additional layers of membrane at weak points such as corners; before applying the membrane to the main surface, mark the positioning lines and open the membrane to release stress, then test-lay the membrane according to the marked lines; the SBS waterproof membrane is applied using the hot-melt method, using a spray gun to appropriately heat the surface of the membrane, and immediately bond it to the base layer or the membrane after the surface is hot-melted, removing any air between the membrane and the base layer before rolling to ensure a firm bond; the overlap width of the membrane should be ≥100mm on the long side and ≥150mm on the short side, with the edge of the overlap seam overflowing with hot-melted modified bitumen, then compact and bond it with a pressure roller; after the waterproof membrane is applied, lay a layer of polyethylene film for isolation, and then pour a 50mm thick C20 fine stone concrete protective layer.

[0015] In this embodiment, the construction of the foundation includes the following steps:

[0016] S1. The foundation reinforcement is tied in two layers, upper and lower. During the reinforcement tying process, protective layer spacers are placed as required.

[0017] S2, Column reinforcement positioning and binding;

[0018] S3. Erection of external scaffolding, positioning and installation of wall panel reinforcement;

[0019] S4. Positioning and installation of embedded parts;

[0020] S5. After the reinforcement of the foundation is inspected and accepted, C30P6 concrete is pumped and poured. Two pumps are used to pour the concrete simultaneously from east to west on the north and south sides of the foundation.

[0021] S6. After the concrete is poured, it should be finished in time and covered with a film for curing.

[0022] In this embodiment, the internal scaffolding is erected, which includes the following steps:

[0023] S1. From west to east, full-span load-bearing scaffolding is erected inside the foundation.

[0024] S2. Scaffolders must be certified and wear safety belts when working at heights. Pedestrian walkways must be erected at the top and bottom of scaffolds to facilitate passage and inspection.

[0025] In this embodiment, the construction includes columns, wall panels, and stairwells. The construction of columns, wall panels, and stairwells includes the following steps:

[0026] S1. Reinforcing steel binding of columns and wall panels;

[0027] S2. Installation and reinforcement of column and wall panel formwork;

[0028] S3. Stairwell formwork installation and reinforcement;

[0029] S4. Stairwell reinforcement binding;

[0030] S5. After the reinforcement and formwork are installed, they shall be inspected and accepted. After the inspection is passed, concrete shall be poured. The wall panels shall be poured in layers and sections, and vibration shall be carried out to ensure that the upper and lower layers of the wall are fully integrated.

[0031] In this embodiment, the construction of a grain conveying ditch includes the following steps:

[0032] S1. Excavation and leveling of the slope of the grain conveying ditch;

[0033] S2. Subbase pouring, brick wall construction, and waterproofing layer construction;

[0034] S3. Binding of ramp foundation reinforcement, installation of embedded parts, setting of reinforcement and wire mesh, dividing of pouring blocks, and skipping pouring to avoid concrete flowing and being unable to accumulate.

[0035] S4. After the steel reinforcement passes inspection, concrete is poured for the ramp foundation, using a pump truck to deliver ready-mixed concrete.

[0036] S5. After the ramp is poured, the wall panels and column reinforcement bars are tied, the full-span scaffolding is erected, the top slab formwork is installed, and the beam reinforcement bars are tied.

[0037] S6. After the top slab reinforcement is tied, the acceptance work is carried out. The same as the slope bottom slab pouring method is used. The pouring is carried out in sections. The concrete slump must be strictly controlled to prevent the concrete from flowing and making it impossible to pour. After pouring, the concrete is covered with a film for curing.

[0038] In this embodiment, the process includes a hydraulic tilting plate foundation and the pouring of the pit top slab. The hydraulic tilting plate foundation and the pouring of the pit top slab include the following steps:

[0039] S1. Control the foundation elevation and install the steel bars and formwork of the hydraulic tilting plate foundation in sequence. Reinforce the formwork firmly to prevent deformation. Uneven inner edges of the foundation will prevent equipment installation from being carried out.

[0040] S2. After the foundation is demolded, the waterproof layer and waterproof protective layer (extruded polystyrene board) are installed. After the construction is completed, backfilling is carried out and the layers are compacted.

[0041] The beneficial effects of this invention are as follows:

[0042] 1. The "layered concrete pouring method" was optimized, which solved the difficult task of layered pouring of the main body of ultra-deep and large-volume grain unloading pit, and reduced the workload and improved work efficiency.

[0043] 2. Due to the large depth of the equipment foundation pit, it is difficult to reinforce the formwork with a single pour. This method reasonably optimizes the anti-expansion reinforcement measures for the formwork, improves work efficiency, and saves construction costs.

[0044] 3. To ensure the quality of the grain conveying ditch pouring, a segmented interval pouring technology for the 9.4° large slope grain conveying ramp was adopted, which effectively solved the problem of difficult concrete forming of the ramp.

[0045] 4. This method effectively solves the problems of cooling during the pouring of large-volume concrete and curing after pouring. Attached Figure Description

[0046] Figure 1 This is a flowchart of the present invention.

[0047] Figure 2 This is a plan view of the foundation pit excavation. Implementation

[0048] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0049] like Figure 1 As shown, a segmented modular casting method for ultra-deep, large-volume grain unloading pit includes the following steps in sequence: measurement, positioning, and layout; foundation trench excavation; subgrade construction; brick wall masonry; waterproof membrane construction; foundation construction; column, wall panel, and stairwell construction; embedded steel column construction; hydraulic tilting plate foundation and top slab casting; ramp excavation and subgrade casting; ramp brick wall masonry; ramp waterproof membrane construction; ramp foundation construction; ramp wall panel and top slab construction; ground casting; and final acceptance.

[0050] In this embodiment, deep foundation pit earthwork construction is included, which comprises the following steps:

[0051] S1. Prepare a special construction plan for deep foundation pits and strictly implement the special construction plan after verification;

[0052] S2. Surveying and Setting Out: Before earthwork excavation, after surveying, positioning, and providing elevations, the upper and lower edges of the excavation site, as well as leveling marks, are set out based on the survey results. This allows for real-time control of the excavation dimensions and elevation during excavation, preventing deviations and over-excavation. After verifying the accuracy of the marked lines based on the axis and elevation, site leveling and excavation are carried out. Once earthwork excavation is complete, the foundation pad is positioned, and the pad soil is manually excavated. All on-site personnel must maintain the survey control points and must not damage them arbitrarily. If a control point is damaged or impacted, the site management personnel should be notified immediately, and its coordinates and elevation should be remeasured.

[0053] S3. Construction of the water-retaining sill and erection of guardrails around the foundation pit; the construction of the water-retaining sill shall be carried out in accordance with the special design plan to prevent rainwater from entering the foundation pit; the water-retaining sill shall be 500mm high, 200mm wide at the top, and 2.0m from the center of the excavation edge of the foundation pit; the site around the foundation pit shall be leveled, and a protective fence shall be erected before excavation. The fence shall consist of two horizontal bars and vertical bars, with a height of not less than 1.20m, a lower bar height of 0.6m from the ground, an upper bar height of 1.2m from the ground, a vertical bar spacing of 2m, and a vertical bar distance of 1.5m from the slope edge. The steel pipes used as guardrails shall be painted with alternating red and white warning colors, safety signs shall be hung on the guardrails, and the area shall be enclosed with dense mesh netting.

[0054] S4. Earthwork excavation shall adhere to the principle of "layered excavation, with strict prohibition of over-excavation." Random excavation, over-excavation, and under-excavation are strictly prohibited. Undercutting for soil extraction is strictly forbidden, and improper excavation methods must be strictly prohibited to prevent slope instability and collapse. See [link / document / details]. Figure 2 .

[0055] When excavating in layers, the depth of each layer shall not exceed 1.5 meters. Excavation shall proceed sequentially from one side, from shallow to deep, and from far to near. The first 300mm above the foundation shall be excavated manually. The last excavation shall be strictly controlled. A level shall be used to control the foundation elevation during excavation, and lime dots shall be sprinkled on the ground to prevent over-excavation. During the excavation process, the foundation pit and the surrounding environment shall be monitored according to the established monitoring plan to provide feedback to guide the construction.

[0056] Drainage ditches and sump pits are constructed at the bottom of the pit for open drainage and dewatering. The sump pits are 0.6m long × 0.6m wide × 0.8m deep and are located at the corner. The drainage ditches have a cross-sectional dimension of 300mm*300mm and slope towards the sump pits. Each sump pit is equipped with a 4-inch sewage pump. The sewage pumps are monitored by designated personnel to promptly pump out the water accumulated in the pits and keep the entire foundation pit dry. The pumped water is discharged to the ditch on the west side through a water hose. To prevent the drainage ditches and sump pits from collapsing, single bricks are laid after the drainage ditches and sump pits are formed, and the surface is coated with 20mm thick waterproof mortar.

[0057] To facilitate workers' access to and from the foundation pit, construction ladders were installed at appropriate locations. The ladders were constructed using Ф48.3 steel pipes, with a width of 1.2 meters. 50mm thick wooden scaffolding boards were laid at the bottom of the platform and inclined runway. Wooden formwork was installed on the inclined runway, with steps 250mm wide and 180mm high. Uprights were inserted into the slope to a depth of at least 500mm. To ensure the stability of the construction access frame, the uprights could be spaced further apart.

[0058] In this embodiment, the foundation construction includes: backfilling and compacting soil, compacting 300mm thick graded crushed stone, and pouring a 200mm thick C20 concrete cushion layer. The concrete used is pumped commercial concrete. After the cushion layer is poured, protective brick walls are built around it. Waterproofing layer laying: the base layer is treated to ensure that it is solid, flat, free of hollow areas, cracks, and water ingress. Detailed nodes are also reinforced. Potholes and damage to the base layer are repaired and leveled with cement mortar. Apply a waterproof coating to the base surface to enhance the adhesion between the base surface and the waterproof membrane; lay additional layers of membrane at weak points such as corners; before applying the membrane to the main surface, mark the positioning lines and open the membrane to release stress, then test-lay the membrane according to the marked lines; the SBS waterproof membrane is applied using the hot-melt method, using a spray gun to appropriately heat the surface of the membrane, and immediately bond it to the base layer or the membrane after the surface is hot-melted, removing any air between the membrane and the base layer before rolling to ensure a firm bond; the overlap width of the membrane should be ≥100mm on the long side and ≥150mm on the short side, with the edge of the overlap seam overflowing with hot-melted modified bitumen, then compact and bond it with a pressure roller; after the waterproof membrane is applied, lay a layer of polyethylene film for isolation, and then pour a 50mm thick C20 fine stone concrete protective layer.

[0059] In this embodiment, the construction of the foundation includes the following steps:

[0060] S1. The foundation reinforcement is tied in two layers, upper and lower. During the reinforcement tying process, protective layer spacers are placed as required.

[0061] S2, Column reinforcement positioning and binding;

[0062] S3. Erection of external scaffolding, positioning and installation of wall panel reinforcement;

[0063] S4. Positioning and installation of embedded parts;

[0064] S5. After the reinforcement of the foundation is inspected and accepted, C30P6 concrete is pumped and poured. Two pumps are used to pour the concrete simultaneously from east to west on the north and south sides of the foundation.

[0065] S6. After the concrete is poured, it should be finished in time and covered with a film for curing.

[0066] In this embodiment, the internal scaffolding is erected, which includes the following steps:

[0067] S1. From west to east, full-span load-bearing scaffolding is erected inside the foundation.

[0068] S2. Scaffolders must be certified and wear safety belts when working at heights. Pedestrian walkways must be erected at the top and bottom of scaffolds to facilitate passage and inspection.

[0069] In this embodiment, the construction includes columns, wall panels, and stairwells. The construction of columns, wall panels, and stairwells includes the following steps:

[0070] S1. Reinforcing steel binding of columns and wall panels;

[0071] S2. Installation and reinforcement of column and wall panel formwork;

[0072] S3. Stairwell formwork installation and reinforcement;

[0073] S4. Stairwell reinforcement binding;

[0074] S5. After the reinforcement and formwork are installed, they shall be inspected and accepted. After the inspection is passed, concrete shall be poured. The wall panels shall be poured in layers and sections, and vibration shall be carried out to ensure that the upper and lower layers of the wall are fully integrated.

[0075] In this embodiment, the construction of a grain conveying ditch includes the following steps:

[0076] S1. Excavation and leveling of the slope of the grain conveying ditch;

[0077] S2. Subbase pouring, brick wall construction, and waterproofing layer construction;

[0078] S3. Binding of ramp foundation reinforcement, installation of embedded parts, setting of reinforcement and wire mesh, dividing of pouring blocks, and skipping pouring to avoid concrete flowing and being unable to accumulate.

[0079] S4. After the steel reinforcement passes inspection, concrete is poured for the ramp foundation, using a pump truck to deliver ready-mixed concrete.

[0080] S5. After the ramp is poured, the wall panels and column reinforcement bars are tied, the full-span scaffolding is erected, the top slab formwork is installed, and the beam reinforcement bars are tied.

[0081] S6. After the top slab reinforcement is tied, the acceptance work is carried out. The same as the slope bottom slab pouring method is used. The pouring is carried out in sections. The concrete slump must be strictly controlled to prevent the concrete from flowing and making it impossible to pour. After pouring, the concrete is covered with a film for curing.

[0082] In this embodiment, the process includes a hydraulic tilting plate foundation and the pouring of the pit top slab. The hydraulic tilting plate foundation and the pouring of the pit top slab include the following steps:

[0083] S1. Control the foundation elevation and install the steel bars and formwork of the hydraulic tilting plate foundation in sequence. Reinforce the formwork firmly to prevent deformation. Uneven inner edges of the foundation will prevent equipment installation from being carried out.

[0084] S2. After the foundation is demolded, the waterproof layer and waterproof protective layer (extruded polystyrene board) are installed. After the construction is completed, backfilling is carried out and the layers are compacted.

[0085] The technological principle of this invention is as follows:

[0086] 1. Deep truck unloading pit with layered pouring

[0087] When pouring concrete, start from the shorter side and pour along the longer side. During the pouring process, the second layer of concrete should be poured before the first layer of concrete has initially set.

[0088] 2. Reinforcement of truck unloading pit formwork

[0089] Reinforcement construction technology refers to reinforcing confined spaces such as ventilation shaft walls and shear walls to enhance their resistance to external interference. The first step is designing the shear wall formwork, aided by large formwork panels and matching nuts. Secondly, construction workers need to accurately calculate the rebar positions when tying the reinforcing bars. After the shear wall formwork is hoisted, the final step is reinforcement, alignment, and concrete pouring. Attention must be paid to the concrete's consistency, density, and other relevant information during its preparation.

[0090] Three-slope ramps were constructed using segmented, skip-section pouring.

[0091] First, during formwork construction, the concrete ramp is divided into sections, each no more than ten meters long. When pouring concrete, the lowest section of the ramp is poured first, followed by the third section after a gap in the middle. After the odd-numbered sections are poured, the even-numbered sections are poured. It is required that the pouring be completed before the initial setting of the two sections.

[0092] 4. Curing of concrete poured for truck unloading pits

[0093] The main maintenance is to maintain suitable temperature and humidity conditions. Water pipes should be buried in the middle of the pouring process to prevent large temperature differences between the inside and outside of the concrete. After pouring, the surface should be covered with a film to prevent excessive evaporation of moisture. Cotton felt should be used to cover the surface to prevent exposure to the sun. After pouring, water should be sprinkled once a day for at least seven days, depending on the situation. Temperature should be checked no less than four times a day. If the temperature difference between the inside and outside of the concrete is found to be close to or greater than 25°C, cold water should be injected into the pre-embedded water pipes for circulation and cooling.

[0094] In this embodiment, quality control is also included:

[0095] 1. Before construction, project technical personnel should carefully familiarize themselves with the drawings, understand the design intent, conduct a thorough review of the drawings, and resolve the problems in the drawings in a timely manner before construction. The project technical responsible person and the construction responsible foreman should provide written交底 on construction requirements, technical operation procedures, and operation methods to the operating teams, and adhere to the "three-inspection system", namely self-inspection, mutual inspection, and handover inspection, to ensure the quality of sub-projects to guarantee the quality of the division project and the quality of the entire project.

[0096] 2. During construction, closely cooperate with the quality inspection and supervision departments. All materials entering the site must have a production license, a certificate of conformity, and a production date, and be inspected and supervised by the construction project quality supervision department. It is strictly prohibited to use products without the "three certificates".

[0097] 3. If any problems are found in the drawings during construction, they should be promptly reported before construction and resolved by the design unit. Subjective assumptions and changes are not allowed. If modifications are necessary due to reasons, they should be jointly studied and determined by the construction unit, the design unit, and the construction unit, and relevant procedures should be completed before modification can be carried out.

[0098] 4. To ensure the quality of the project, all building materials and equipment used in this project should comply with relevant quality standards. The selection of building materials and the determination of colors should be jointly studied and determined by the construction unit, the design unit, and the construction unit.

[0099] 5. All holes and embedded parts must be reserved or embedded in coordination with relevant trades. Post - drilling is strictly prohibited. Reinforcement bars should bypass the hole edges. If it is necessary to cut off reinforcement bars, additional reinforcement bars must be added at the hole edges.

[0100] 6. The second - stage decoration design part should be jointly studied with the design unit, and attention should be paid to the arrangement of positions such as fire sprinkler heads, detectors, ventilation openings, and lamps, and it should meet the fire requirements.

[0101] 7. All pipelines passing through the floor or reserved holes marked in the drawings should be reserved and embedded in close coordination with the relevant professional drawings. Post - drilling is not allowed.

[0102] 8. The selection of reinforcement bars strictly follows the design requirements, and the binding is carried out strictly in accordance with the technological process. The qualified rate of reinforcement bar binding is required to be over 95%.

[0103] 9. During the formwork support process, strengthen the strength requirements of the support structure, ensure sufficient strength, rigidity, and stability, check the application of formwork release agent, and the width of formwork joints shall not be greater than 1.5 mm.

[0104] 10. Strictly control the treatment methods for the influence of cement hydration heat and the change of external air temperature in accordance with the specified construction plan, and control the quality problems of concrete shrinkage deformation. Strengthen the inspection of the deformation of the support structure during the pouring process, ensure that the deformation amount is within the controllable range, and control the appearance quality.

[0105] In this embodiment, safety measures are also included:

[0106] 1. The project team must strictly implement the Party and the State's relevant guidelines, policies, laws, and safety technical regulations on work safety. A safety responsibility system must be established at the construction site, and a sound safety organization must be in place. While managing production, the team must also be responsible for managing safety. All technical personnel and workers must be responsible for work safety within their respective areas of expertise or production positions.

[0107] 2. A sound safety management network must be established at the construction site, and detailed safety management rules must be formulated. The project department shall be equipped with a full-time safety officer, and each work team shall have a part-time safety officer. Before the start of the project, there must be a construction organization design and targeted safety technical measures. There must be a written technical briefing system for the construction site.

[0108] 3. Construction site management personnel must wear identification badges or cards and regularly check safety regulations and inspection records. Any identified safety hazards must be assigned to specific individuals, with defined timelines and corrective measures, and rectification notices must be issued. A safety education system must be established, providing three levels of safety training to new workers, with clearly defined training content. Full-time safety officers must undergo annual training and assessment. A pre-shift safety activity system must be established and recorded, and the construction site must have safety signs and a site plan.

[0109] 4. All construction workers entering the site must possess the "three treasures" of personal protective equipment ("three essential items"). Every employee must maintain civilized construction practices, keep the site clean, and stack materials neatly. Safety signs must be posted at the site, roads, drainage outlets, and hazardous areas. On-site dormitories must have fire prevention measures, regulations, and fire extinguishers. A gatekeeper security system must be established, and safety slogans must be displayed on-site. Regarding living facilities: canteen staff must have work permits and health certificates. The hygiene of the drinking water supplied to employees must be guaranteed.

[0110] 5. All machinery operators must be trained according to regulations and pass an examination before being allowed to operate the machinery. Working without a license is strictly prohibited. Electrical equipment on the construction site must be installed according to electrical regulations. On-site electrical use must have protective measures in place, and a three-phase five-wire system must be used. The "one machine, one switch, one leakage protector, one distribution box" rule must be strictly enforced. Non-electricians are prohibited from haphazardly connecting or installing electrical wiring. Installation, maintenance, and dismantling of temporary electrical systems must be completed by certified electricians.

[0111] This embodiment also includes environmental protection measures:

[0112] 1. Establish an HSE management system for the construction site, strictly abide by the laws, regulations and rules on environmental protection and civilized construction formulated by the national and local governments and the owner, strengthen the control and management of construction materials, equipment, wastewater, domestic and industrial waste and slag, and comply with the relevant regulations on fire prevention and waste disposal.

[0113] 2. Harden the roads within the construction area, set up high-pressure washing machines at the entrances and exits of the construction site, and assign dedicated personnel to wash the roads to prevent dirt, mud, and sand from leaving the site, ensuring that the finished roads are unobstructed and the municipal roads are clean.

[0114] 3. Dust suppression water trucks will be set up around the construction site regularly to carry out dust suppression work in the construction area. Slopes and ash piles will be fully covered with dustproof mesh netting to prevent dust pollution and protect the cleanliness of the concrete surface during pouring. The height of the bricks and mortar on earthmoving vehicles should not exceed the side of the truck bed, and the distance between the bricks and mortar should be more than 5 cm from the top of the side of the truck bed. The top of the vehicles should be covered with colored tarpaulins to prevent soil and mortar from falling off.

[0115] 4. Set up centralized steel reinforcement sheds and carpentry sheds to reduce corresponding noise and dust pollution.

[0116] The benefits of this invention are analyzed as follows:

[0117] This construction method optimizes the segmented modular casting technology for ultra-deep, large-volume grain unloading pits, reducing most of the formwork, timber materials, and labor. This adjustment to the construction method further reduced manpower and working hours. Simultaneously, the concrete pouring sequence and method were rationally optimized, and attention was paid to controlling the quality of concrete pouring in detail, ensuring both pouring efficiency and quality.

[0118] Taking a company's 2.4 million tons / year corn deep processing and storage ancillary facility construction project as an example, from March to July 2022, this construction method was used for the segmented modular pouring of ultra-deep, large-volume unloading pits. The project took 94 working days, 20 days ahead of the owner's expected time (114 days), shortening the construction period by approximately 17.5%, saving 134,000 yuan in costs, and increasing the profit margin by 10%. Compared to traditional concrete pouring methods, this new technology, using segmented and modular pouring in later construction projects, achieves the same or even better progress and economic benefits.

[0119] Engineering application examples of this invention:

[0120] With the development of the national economy and driven by advanced science and technology, China's concrete technology has developed rapidly. The increasing number of large-scale buildings places increasingly higher demands on large-volume concrete construction technology. Given that there is still room for improvement in concrete construction technology, it is essential to actively conduct research on concrete construction techniques.

[0121] Currently, mass concrete construction is widely used in the construction industry. However, due to the numerous challenges of this construction technique and the lack of standardized skills among construction workers, the quality of the concrete is significantly affected. Therefore, it is crucial to grasp the key points of concrete construction, from raw material selection and mix proportions to concrete pouring and temperature control, all of which require strict adherence to ensure the quality of mass concrete construction.

[0122] The segmented modular casting technology for the ultra-deep, large-volume grain unloading pit in this project not only improves work efficiency and reduces costs, but also has superior quality and aesthetic appeal, and has broad application prospects.

[0123] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications are also considered within the scope of protection of this invention.

Claims

1. A segmented modular casting method for ultra-deep, large-volume grain unloading pits, characterized in that, The project includes the following steps in sequence: measurement, positioning, and layout; foundation trench excavation; subbase construction; brick wall masonry; waterproof membrane installation; foundation construction; column, wall panel, and stairwell construction; embedded steel column construction; hydraulic tilting slab foundation and roof slab pouring; ramp excavation and subbase pouring; ramp brick wall masonry; ramp waterproof membrane installation; ramp foundation construction; ramp wall panel and roof slab construction; ground pouring; and final acceptance. This includes the construction of grain conveying ditches, which includes the following steps: S1. Excavation and leveling of the slope of the grain conveying ditch; S2. Subbase pouring, brick wall construction, and waterproofing layer construction; S3. Binding of ramp foundation reinforcement, installation of embedded parts, setting of reinforcement and wire mesh, dividing of pouring blocks, and skipping pouring to avoid concrete flowing and being unable to accumulate. S4. After the steel reinforcement passes inspection, concrete is poured for the ramp foundation, using a pump truck to deliver ready-mixed concrete. S5. After the ramp is poured, the wall panels and column reinforcement bars are tied, the full-span scaffolding is erected, the top slab formwork is installed, and the beam reinforcement bars are tied. S6. After the top slab reinforcement is tied, the acceptance work is carried out. The same as the slope bottom slab pouring method is used. The pouring is carried out in sections. The concrete slump must be strictly controlled to prevent the concrete from flowing and making it impossible to pour. After pouring, the concrete is covered with a film for curing.

2. The segmented modular casting method for ultra-deep, large-volume grain unloading pits according to claim 1, characterized in that, This includes deep foundation pit earthwork construction, which includes the following steps: S1. Prepare a special construction plan for deep foundation pits and strictly implement the special construction plan after verification; S2. Surveying and setting out: Before earthwork excavation, after surveying, positioning, and providing elevation, the upper and lower edge lines and leveling marks of the earthwork excavation are set out based on the survey results. After verifying that the gray lines set out based on the axis and elevation are correct, site leveling and excavation work are carried out. After the earthwork excavation is completed, the positioning of the foundation cushion layer is carried out in a timely manner, and then the cushion layer soil is manually excavated. S3. Construction of the water-retaining sill around the foundation pit and erection of the guardrail; the water-retaining sill shall be constructed in accordance with the special design plan to prevent rainwater from entering the foundation pit; the water-retaining sill shall be 500mm high, 200mm wide at the top, and 2.0m from the center of the excavation edge of the foundation pit; the site around the foundation pit shall be leveled, and a protective fence shall be erected before excavation. The fence shall consist of two horizontal bars and vertical bars, with a height of not less than 1.20m, a lower bar height of 0.6m from the ground, an upper bar height of 1.2m from the ground, a vertical bar spacing of 2m, and a vertical bar distance of 1.5m from the slope edge. The steel pipes used as guardrails shall be painted with alternating red and white warning colors, safety signs shall be hung on the guardrails, and the area shall be enclosed with dense mesh netting. S4. Earthwork excavation shall follow the principle of "layered excavation and strict prohibition of over-excavation". It is forbidden to excavate randomly, over-excavate or under-excavate. It is strictly forbidden to dig holes to extract soil. Furthermore, it is forbidden to cause slope instability or collapse due to improper excavation methods.

3. The segmented modular casting method for ultra-deep, large-volume grain unloading pit according to claim 1, characterized in that, The foundation construction includes: backfilling and compaction of soil, compaction of 300mm thick graded crushed stone, and pouring of a 200mm thick C20 concrete cushion layer (using pumped ready-mixed concrete). After the cushion layer is poured, protective brick walls are built around it. Waterproofing layer installation involves: treating the base layer to ensure it is solid, flat, free of hollow areas, cracks, and water ingress; reinforcing details at joints; repairing and leveling any pits or damage with cement mortar; spraying waterproof coating onto the base surface to enhance adhesion between the base surface and the waterproof membrane; applying additional membrane layers to weak points such as corners; and pre-applying a weathering board before applying the membrane to the main surface. Position the membrane along the lines and unroll it to release stress. First, test-lay the membrane according to the marked lines on the plane. For SBS waterproof membrane, use the hot-melt method. Use a spray gun to appropriately heat the membrane surface. Once the membrane surface is hot-melted, immediately adhere it to the substrate or the base layer. After removing air from between the membrane and the substrate, roll it firmly. The overlap width of the membrane should be ≥100mm on the long side and ≥150mm on the short side. The edge of the overlap should allow hot-melted modified bitumen to overflow. Then, use a pressure roller to compact and adhere it. After the waterproof membrane is installed, lay a layer of polyethylene film for isolation, and then pour a 50mm thick C20 fine stone concrete protective layer.

4. The segmented modular casting method for an ultra-deep, large-volume grain unloading pit according to claim 1, characterized in that, This includes the construction of the foundation, which includes the following steps: S1. The foundation reinforcement is tied in two layers, upper and lower. During the reinforcement tying process, protective layer spacers are placed as required. S2, Column reinforcement positioning and binding; S3. Erection of external scaffolding, positioning and installation of wall panel reinforcement; S4. Positioning and installation of embedded parts; S5. After the reinforcement of the foundation is inspected and accepted, C30P6 concrete is pumped and poured. Two pumps are used to pour the concrete simultaneously from east to west on the north and south sides of the foundation. S6. After the concrete is poured, it should be finished in time and covered with a film for curing.

5. The segmented modular casting method for ultra-deep, large-volume grain unloading pit according to claim 1, characterized in that, This includes the erection of internal scaffolding, which comprises the following steps: S1. From west to east, full-span load-bearing scaffolding is erected inside the foundation. S2. Scaffolders must be certified and wear safety belts when working at heights. Pedestrian walkways must be erected at the top and bottom of scaffolds to facilitate passage and inspection.

6. The segmented modular casting method for an ultra-deep, large-volume grain unloading pit according to claim 1, characterized in that, This includes the construction of columns, wall panels, and stairwells, and the construction of columns, wall panels, and stairwells includes the following steps: S1. Reinforcing steel binding of columns and wall panels; S2. Installation and reinforcement of column and wall panel formwork; S3. Stairwell formwork installation and reinforcement; S4. Stairwell reinforcement binding; S5. After the reinforcement and formwork are installed, they shall be inspected and accepted. After the inspection is passed, concrete shall be poured. The wall panels shall be poured in layers and sections, and vibration shall be carried out to ensure that the upper and lower layers of the wall are fully integrated.

7. The segmented modular casting method for an ultra-deep, large-volume grain unloading pit according to claim 1, characterized in that, This includes the construction of a hydraulic tilting slab foundation and the pouring of the pit top slab. The construction of the hydraulic tilting slab foundation and the pouring of the pit top slab includes the following steps: S1. Control the foundation elevation and install the steel bars and formwork of the hydraulic tilting plate foundation in sequence. Reinforce the formwork firmly to prevent deformation. Uneven inner edges of the foundation will prevent equipment installation from being carried out. S2. After the foundation is demolded, the waterproof layer and waterproof protective layer are installed. After the construction is completed, backfilling is carried out and the layers are compacted.

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