Prefabricated assembly type pier column bent cap construction method

Abstract

This invention relates to a construction method for precast assembled pier and cap beam, comprising the following steps: cast-in-place foundation construction, installation of the first precast pier section, precast pier extension construction, precast cap beam installation, and steel cross bracing installation. The beneficial effects of this invention are: it achieves efficient connection technology between precast piers and foundations. Precast piers can be quickly and stably connected to cast-in-place foundations with core columns via their own shear grooves, or quickly and stably connected to precast pipe piles via connecting steel pipe sections with upper flanges. The operation is simple and widely applicable. A technical solution for installing steel cross bracing using auxiliary wheel sets is proposed. Utilizing the already installed precast cap beam as a platform, the combined use of auxiliary wheel sets, winches, and cable-stayed bridges achieves efficient installation of the steel cross bracing, with controllable installation speed, high construction safety, and solves the problem of large hoisting equipment being unable to enter certain sites.

Description

Technical Field

[0001] This invention belongs to the field of bridge engineering, and in particular relates to a construction method for prefabricated assembled pier column cap beams. Background Technology

[0002] In bridge construction, the construction of bridge piers and cap beams mostly adopts cast-in-place construction. However, in recent years, engineering construction has been developing towards standardization and factory production, giving rise to prefabricated bridges. Prefabricated bridges, due to the factory production of components, can utilize mechanized, standardized, and automated production lines to standardize a large amount of repetitive work on the construction site. Combined with the standardization and modularization of components, this significantly improves labor efficiency and reduces labor costs. Practical engineering projects have shown that prefabricated bridge construction technology can save 40% of the construction period, 50% of labor requirements, and 60% of the need for production sites.

[0003] Currently, numerous studies and practices have been conducted on prefabricated bridges both domestically and internationally. However, some processes still suffer from cumbersome procedures and low construction efficiency. For example, there is the issue of leveling the prefabricated pier and foundation layer: traditional leveling of the prefabricated pier and foundation layer often involves manual leveling with small tools, which is difficult to handle not only the corners but also to control the overall flatness. Furthermore, existing leveling machinery is not well-suited for such special working conditions. Another example is the installation of connecting components between prefabricated piers on rugged road sections. Current technology typically involves erecting manual ladders on both sides of the prefabricated piers and using cranes for hoisting and manual assistance. This method results in high equipment rental costs and stringent entry conditions for large equipment, limiting its applicability.

[0004] In view of this, there is an urgent need to invent a construction method for prefabricated bridge components that is fast, has low construction risk, and has outstanding economic and technical benefits. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a construction method for prefabricated assembled pier and cap beams.

[0006] This prefabricated assembly pier cap beam construction method includes the following steps:

[0007] S1. Cast-in-place foundation construction: Cast the cast-in-place foundation and reserve the annular post-pouring cup opening. Epoxy mortar is laid at the bottom of the annular post-pouring cup opening and leveled using the cup opening leveling device to form a cup opening leveling layer.

[0008] S2. Installation of the first precast pier column: The first precast pier column is hoisted into the reserved annular post-pouring cup of the cast-in-place foundation and the post-pouring cup concrete is poured.

[0009] S3. Construction of precast pier extension: On the first precast pier, several pier sections are extended by anchoring the upper and lower flanges. The main reinforcement of the precast pier is reserved at the top of the last precast pier.

[0010] S4. Installation of precast cap beam: The precast cap beam is hoisted to the top of the last precast pier column, the pre-embedded grouting sleeve is aligned with the main reinforcement of the precast pier, and the pre-embedded grouting sleeve is grouted.

[0011] S5. Steel cross bracing installation: Steel cross bracing is installed between the connecting piers by sliding and lifting with auxiliary wheel sets.

[0012] Preferably, in step S1, the foundation soil is excavated according to the pile foundation coordinates, the reinforcing steel of the cast-in-place pile cap is tied, the cast-in-place pile cap is reserved with a ring-shaped post-casting cup, the steel formwork is erected and the concrete is poured, and the steel formwork is removed after curing to form the cast-in-place pile cap; the cup leveling device includes a main adjusting rod, a secondary telescopic rod, a diagonal brace, an anti-slip base and a leveling end plate. The main adjusting rod abuts against the cup wall of the cast-in-place pile cap through the diagonal braces on both sides. An anti-slip base is set at the end of the diagonal brace near the cup of the cast-in-place pile cap. The lower end of the main adjusting rod is connected to the secondary telescopic rod, and the secondary telescopic rod is equipped with a ring-shaped leveling end plate.

[0013] Preferably, the annular post-pouring cup of the cast-in-place pier is provided with a pier core column. In step S2, the first precast pier column is hoisted to the top of the cast-in-place pier by hoisting equipment. After the center of the first precast pier column is initially aligned with the center of the cast-in-place pier core column, it is lowered until the pier core column is completely embedded in the first precast pier column. Then, concrete is poured in the reserved annular post-pouring cup to complete the installation of the first precast pier column.

[0014] Preferably, in step S2, when the first precast pier column is connected to the pile foundation, the top of the pile foundation is provided with a lower flange, and the bottom of the first precast pier column is directly connected to the lower flange provided at the top of the pile foundation through an upper flange; the bottom of the first precast pier column is provided with a shear groove, and the bottom of the first precast pier column directly connected to the pile foundation is also provided with a connecting section steel pipe, the inner wall of the connecting section steel pipe is provided with shear nails, and the lower end is provided with an upper flange.

[0015] Preferably, in step S2, a pile end clamp is provided at the top of the pile foundation, and the pile end clamp is provided with a lower flange. The bottom of the lower flange is also connected and fixed to the main reinforcement of the pile foundation through a connecting lock.

[0016] As a preferred option, after the construction of the last precast pier column is completed, epoxy mortar is laid on the top of the last precast pier column, and the pier top leveling device is used to uniformly level it to form a pier top leveling layer. The pier top leveling device includes an outer ring slide rail sleeve and an inner ring slide rail sleeve. Anti-slip pads are provided on the inner wall of the outer ring slide rail sleeve and the outer wall of the inner ring slide rail sleeve. A fan-shaped outer ring leveling plate is provided inside the outer ring slide rail sleeve wall, and a fan-shaped inner ring leveling plate is provided inside the inner ring slide rail sleeve wall.

[0017] Preferably, a pre-embedded grouting sleeve is provided in the center of the precast cap beam. In step S4, the precast cap beam is hoisted to the top of the last precast pier column by hoisting equipment. After aligning the pre-embedded grouting sleeve with the main reinforcement of the precast pier, it is lowered and installed on the leveling layer at the top of the pier, and the grouting work of the pre-embedded grouting sleeve is completed.

[0018] Preferably, in step S5, steel cross braces are installed between the connecting piers via auxiliary wheel sets. The ends of the connecting piers are provided with connecting steel pipe sections. Each set of steel cross braces is welded to the connecting steel pipe section. The auxiliary wheel sets are symmetrically arranged on the sides of the two precast cap beams. The precast cap beams are fixed with connecting cross plates by anchor bolts. The auxiliary wheel sets are respectively anchored to the connecting cross plates by connecting bolts. A sliding cable is provided on the auxiliary wheel sets. One end of the sliding cable is connected to a winch on the ground, and the other end is connected to a lifting ring on the steel cross brace via a hook.

[0019] As a preferred option, in step S5, a crushed stone cushion layer is laid directly on the foundation within the foundation leveling construction area, and a mortar leveling layer is poured on the crushed stone cushion layer. Steel cross bracing is then installed by erecting a full-span scaffold.

[0020] The precast assembled pier cap beam is obtained by any of the methods described above.

[0021] The beneficial effects of this invention are:

[0022] 1) This invention realizes an efficient connection technology between precast piers and foundations. Precast piers can be quickly and stably connected to cast-in-place foundations with core columns via their own shear grooves, or they can be quickly and stably connected to precast pipe piles via connecting steel pipe sections with upper flanges. The operation is simple and the applicability is wide.

[0023] 2) This invention proposes a technical solution for installing steel cross braces using auxiliary wheel sets. Utilizing precast cap beams already in place as a platform, auxiliary wheel sets, winches, and cable-stayed connections are combined to achieve efficient installation of the steel cross braces. The installation speed is controllable, construction safety is high, and this solution addresses the problem of large hoisting equipment being unable to access certain sites.

[0024] 3) This invention develops a cup-mouth leveling device and a pier-top leveling device. These two leveling devices enable efficient and high-quality on-site leveling operations, are easy to operate, have low manufacturing costs, and are reusable, resulting in significant economic benefits. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the prefabricated assembled pier-column cap beam structure system in this invention;

[0026] Figure 2 This is a cross-sectional view of the cup leveling device in this invention;

[0027] Figure 3This is a top view of the cup leveling device in this invention;

[0028] Figure 4 This is a schematic diagram of the connection between the precast pier and the cast-in-place foundation in this invention;

[0029] Figure 5 This is a schematic diagram of the connection between the precast pier and the pile foundation in this invention;

[0030] Figure 6 This is a schematic diagram of the construction of the auxiliary wheel assembly steel cross brace in this invention;

[0031] Figure 7 This is a schematic diagram of the connection between the auxiliary wheel assembly and the precast cap beam in this invention;

[0032] Figure 8 This is a schematic diagram of the construction of the steel cross bracing for the full-span scaffold in this invention;

[0033] Figure 9 This is a cross-sectional view of the pier top leveling device in this invention;

[0034] Figure 10 This is a top view of the pier top leveling device in this invention.

[0035] In the diagram: 1-Support; 2-Precast cap beam; 3-Leveling layer at the pier top; 4-Connecting pier column; 5-Upper flange; 6-Post-cast cup-mouth concrete; 7-Cast-in-place pile cap; 8-Pile cap foundation; 9-Steel cross brace; 10-Grouting sleeve; 11-Last precast pier column; 12-Lower flange; 13-First precast pier column; 14-Pile cap core column; 15-Cup-mouth leveling layer; 16-Main adjusting rod; 17-Diagonal brace; 18-Anti-slip base; 19-Leveling end plate; 20-Secondary telescopic rod; 21-Shear groove; 22-Shear nail; 2 3-Connecting steel pipe; 24-Pile end clamp; 25-Precast pier main reinforcement; 26-Connecting lock; 27-Pile foundation main reinforcement; 28-Pile foundation; 29-Sliding cable; 30-Wind; 31-Auxiliary wheel set; 32-Lifting ring; 33-Lifting hook; 34-Connecting bolt; 35-Anchoring bolt; 36-Connecting horizontal plate; 37-Full-span support; 38-Mortar leveling layer; 39-Crushed stone cushion layer; 40-Outer ring leveling plate; 41-Outer ring slide rail sleeve; 42-Inner ring leveling plate; 43-Inner ring slide rail sleeve; 44-Anti-slip washer. Detailed Implementation

[0036] The present invention will be further described below with reference to embodiments. The description of the embodiments below is only for the purpose of helping to understand the present invention. It should be noted that those skilled in the art can make several modifications to the present invention without departing from the principle of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

[0037] Example 1

[0038] As one example, such as Figures 1 to 10 As shown, this prefabricated assembled pier cap beam construction method includes the following steps:

[0039] S1. Construction of cast-in-place pile cap: Excavate the foundation soil according to the coordinate of pile foundation 28, tie the pile cap reinforcement, reserve the ring-shaped post-cast cup opening in the pile cap, set up the steel formwork and then pour concrete. After curing, remove the steel formwork to form cast-in-place pile cap 7. Epoxy mortar is laid at the bottom of the cup opening of cast-in-place pile cap 7 and leveled using the cup opening leveling device to form cup opening leveling layer 15.

[0040] S2. Installation of the first precast pier column: The first precast pier column 13 is hoisted to the top of the cast-in-place foundation 7 by hoisting equipment. After the center of the first precast pier column 13 is initially aligned with the center of the core column of the cast-in-place foundation 7, it is slowly lowered until the core column 14 of the foundation is completely embedded in the precast pier column. Then, the post-casting cup concrete 6 is poured into the reserved annular post-casting cup to complete the installation of the first precast pier column 13. In particular, in some places where the cast-in-place foundation 7 is not set, the first precast pier column 13 can be directly connected to the lower flange 12 set at the top of the pile foundation 28 through the upper flange 5 set at the end of the pier column.

[0041] S3. Construction of precast pier extension: Based on the first precast pier 13, the pier is vertically extended to the design elevation by means of pile splicing. All precast piers are connected by anchoring the upper flange 5 and the lower flange 12. The top of the last precast pier 11 is reserved with the main reinforcement 25 of the precast pier.

[0042] Construction of the leveling layer of the last precast pier column: Epoxy mortar is laid on the top of the last precast pier column 11 and leveled uniformly by the pier top leveling device to form the pier top leveling layer 3.

[0043] S4. Installation of precast cap beam: The precast cap beam 2 is hoisted to the top of the last precast pier column 11 by hoisting equipment. After aligning the pre-embedded grouting sleeve 10 with the main reinforcement 25 of the last precast pier, it is slowly lowered and installed on the pier top leveling layer 3. The grouting work of the pre-embedded grouting sleeve 10 is completed within the working time of the grouting material.

[0044] S5. Steel cross bracing installation: Steel cross bracing 9 is installed between precast piers by sliding the auxiliary wheel set 31. Each set of steel cross bracing 9 is welded to the steel pipe 23 of the precast pier connecting section. In particular, in the foundation leveling construction area, a crushed stone cushion layer 39 can be laid directly on the foundation and a mortar leveling layer 38 can be poured. The steel cross bracing 9 is installed by erecting a full-span scaffold 37.

[0045] Example 2

[0046] As another embodiment, this second embodiment proposes a more specific construction method for prefabricated assembled pier-column cap beams based on the first embodiment.

[0047] In step S1, the leveling device for the 28 cup opening of the pile foundation consists of a main adjusting rod 16, a secondary telescopic rod 20, a diagonal brace 17, an anti-slip base 18, and a leveling end plate 19. The main adjusting rod 16 abuts against the cup opening wall of the cast-in-place pile cap 7 through the diagonal braces 17 on both sides. An anti-slip base 18 is provided at the end of the diagonal brace 17 near the cup opening of the cast-in-place pile cap 7. The lower end of the main adjusting rod 16 is connected to the secondary telescopic rod 20, and the secondary telescopic rod 20 is equipped with an annular leveling end plate 19.

[0048] In step S2, the bottom of the first precast pier column 13 is provided with a shear groove 21. The bottom of the first precast pier column 13, which is directly connected to the pile foundation 28, is also provided with a connecting section steel pipe 23. The inner wall of the connecting section steel pipe 23 is provided with shear nails 22, and the end is provided with an upper flange 5.

[0049] The top of the pile foundation 28 is provided with a pile end clamp 24, and the pile end clamp 24 is provided with a lower flange 12. The lower flange 12 is also connected and fixed to the main reinforcement 27 of the pile foundation through an internal connection lock.

[0050] In step S3, the pier top leveling device mainly consists of an outer ring slide rail sleeve 41 and an inner ring slide rail sleeve 43. Anti-slip washers 44 are provided on the inner wall of the outer ring slide rail sleeve 41 and the outer wall of the inner ring slide rail sleeve 43. A fan-shaped outer ring adjusting plate 40 is provided inside the wall of the outer ring slide rail sleeve 41, and a fan-shaped inner ring adjusting plate 42 is provided inside the wall of the inner ring slide rail sleeve 43. Both the inner and outer adjusting plates can move circumferentially within the slide rail.

[0051] In step S4, the auxiliary wheel set 31 is symmetrically arranged on both sides of the precast cover beam 2 and is anchored to the connecting horizontal plate 36 by connecting bolts 34. The connecting horizontal plate 36 is connected and fixed to the precast cover beam 2 by anchor bolts 35. The auxiliary wheel set 31 is equipped with a sliding cable 29. One end of the sliding cable 29 is connected to the ground winch 30, and the other end is connected to the lifting ring 32 on the steel cross brace 9 by the hook 33.

[0052] It should be noted that the parts in this embodiment that are the same as or similar to those in Embodiment 1 can be referred to each other, and will not be repeated in this application.

[0053] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

Claims

1. A construction method for prefabricated assembled pier-column cap beams, characterized in that: Includes the following steps: S1. Cast-in-place foundation construction: Cast the cast-in-place foundation and reserve the annular post-pouring cup opening. Epoxy mortar is laid at the bottom of the annular post-pouring cup opening and leveled using the cup opening leveling device to form a cup opening leveling layer. S2. Installation of the first precast pier column: The first precast pier column is hoisted into the reserved annular post-pouring cup of the cast-in-place foundation and the post-pouring cup concrete is poured. S3. Construction of precast pier extension: On the first precast pier, several pier sections are extended by anchoring the upper and lower flanges. The main reinforcement of the precast pier is reserved at the top of the last precast pier. S4. Installation of Precast Cap Beam: The precast cap beam is hoisted to the top of the last precast pier column. The pre-embedded grouting sleeve is aligned with the main reinforcement of the precast pier, and grouting is performed on the pre-embedded grouting sleeve. After the construction of the last precast pier column is completed, epoxy mortar is laid on the top of the last precast pier column, and leveling is performed uniformly through the pier top leveling device to form a pier top leveling layer. The pier top leveling device includes an outer ring slide rail sleeve and an inner ring slide rail sleeve. Anti-slip pads are provided on the inner wall of the outer ring slide rail sleeve and the outer wall of the inner ring slide rail sleeve. A fan-shaped outer ring leveling plate is provided inside the outer ring slide rail sleeve, and a fan-shaped inner ring leveling plate is provided inside the inner ring slide rail sleeve. A pre-embedded grouting sleeve is provided in the center of the precast cap beam. The precast cap beam is hoisted to the top of the last precast pier column by hoisting equipment. After aligning the pre-embedded grouting sleeve with the main reinforcement of the precast pier, it is lowered and installed on the pier top leveling layer, and the grouting work of the pre-embedded grouting sleeve is completed. S5. Steel cross bracing installation: Steel cross bracing is installed between the connecting piers by sliding and lifting with auxiliary wheel sets.

2. The construction method for prefabricated assembled pier-column cap beams according to claim 1, characterized in that, In step S1, the foundation soil is excavated according to the pile foundation coordinates, the reinforcing steel of the cast-in-place pile cap is tied, the cast-in-place pile cap is reserved with a ring-shaped post-casting cup, the steel formwork is erected and the concrete is poured, and the steel formwork is removed after curing to form the cast-in-place pile cap; the cup leveling device includes a main adjusting rod, a secondary telescopic rod, a diagonal brace, an anti-slip base and a leveling end plate. The main adjusting rod abuts against the cup wall of the cast-in-place pile cap through the diagonal braces on both sides. An anti-slip base is set at the end of the diagonal brace near the cup of the cast-in-place pile cap. The lower end of the main adjusting rod is connected to the secondary telescopic rod, and the secondary telescopic rod is equipped with a ring-shaped leveling end plate.

3. The construction method for prefabricated assembled pier-column cap beams according to claim 1, characterized in that, The annular post-pouring cup of the cast-in-place pier cap has a core column. In step S2, the first precast pier column is hoisted to the top of the cast-in-place pier cap by hoisting equipment. After the center of the first precast pier column is initially aligned with the center of the core column of the cast-in-place pier cap, it is lowered until the core column of the pier cap is completely embedded in the first precast pier column. Then, concrete is poured in the reserved annular post-pouring cup to complete the installation of the first precast pier column.

4. The construction method for prefabricated assembled pier-column cap beams according to claim 1, characterized in that, In step S2, when the first precast pier column is connected to the pile foundation, a lower flange is provided at the top of the pile foundation, and the bottom of the first precast pier column is directly connected to the lower flange provided at the top of the pile foundation through an upper flange; a shear groove is provided at the bottom of the first precast pier column, and a connecting section steel pipe is also provided at the bottom of the first precast pier column directly connected to the pile foundation. Shear nails are provided on the inner wall of the connecting section steel pipe, and an upper flange is provided at the lower end.

5. The construction method for prefabricated assembled pier-column cap beams according to claim 4, characterized in that, In step S2, a pile end clamp is installed at the top of the pile foundation, and a lower flange is installed on the pile end clamp. The bottom of the lower flange is also connected and fixed to the main reinforcement of the pile foundation through a connecting lock.

6. The construction method for prefabricated assembled pier-column cap beams according to claim 1, characterized in that, In step S5, steel cross braces are installed between the connecting piers via auxiliary wheel sets. The ends of the connecting piers are equipped with connecting steel pipe sections. Each set of steel cross braces is welded to the connecting steel pipe section. The auxiliary wheel sets are symmetrically arranged on the sides of the two precast cap beams. The precast cap beams are fixed with connecting cross plates by anchor bolts. The auxiliary wheel sets are anchored to the connecting cross plates by connecting bolts. A sliding cable is installed on the auxiliary wheel sets. One end of the sliding cable is connected to a winch on the ground, and the other end is connected to a lifting ring on the steel cross brace via a hook.

7. The construction method for prefabricated assembled pier-column cap beams according to claim 6, characterized in that, In step S5, within the foundation leveling construction area, a crushed stone cushion layer is laid directly on the foundation, and a mortar leveling layer is poured on the crushed stone cushion layer. Steel cross bracing is then installed by erecting a full-span scaffold.

8. A precast assembled pier cap beam, characterized in that, Obtained by the method described in any one of claims 1 to 7.

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