Method and device for one-time casting of special-shaped high pier

Abstract

This invention relates to the field of pier construction, providing a method and apparatus for one-time casting and forming of irregularly shaped high piers. The forming method is as follows: 1. Constructing a casting mold, which includes a pier body mold, two sets of arch molds, and a cap beam mold arranged sequentially from bottom to top. The two sets of arch molds are supported above the pier body mold and form a Y-shaped structure with it. 2. Grouting is injected into the pier body mold through a skylight located at the upper end of the pier body mold between the two sets of arch molds until the pier body is cast. 3. Grouting is injected into the two sets of arch molds through openings at their upper ends, completing the casting of the arches and cap beam sequentially from bottom to top. The forming method and apparatus of this invention first casts the pier body mold, which is vertical and has a skylight reserved at the top to facilitate grouting and vibration operations inside the pier body mold, as well as the insertion and lifting of the tremie pipe, avoiding concrete segregation. The two sets of arches and the cap beam are cast in one go, saving construction time and reducing construction difficulty.

Description

Technical Field

[0001] This invention relates to the field of pier construction, and more specifically, to a method and apparatus for one-time casting and molding of irregularly shaped high piers. Background Technology

[0002] In traditional bridge pier construction, concrete is poured layer by layer within a mold until the pier body and the cap beam above it are formed. In this type of pier construction, since the cap beam is usually placed directly above the pier body, the pier body mold can be completed and dismantled before the cap beam mold is built and the cap beam is poured. This construction technique is relatively mature and convenient. However, for the construction of irregular piers (such as Y-shaped piers), the cap beam is supported by two sets of spandrel arches. The traditional construction method is to construct the pier body, the two sets of spandrel arches, and the cap beam in sequence. That is, after the pier body is formed, the spandrel arches are constructed, and after the spandrel arches are formed and the molds are removed, the cap beam is constructed. This construction sequence is cumbersome and complex, and the construction period is long.

[0003] For the reasons mentioned above, it is necessary to provide a one-time casting molding scheme and molding device for irregular heights. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a one-time casting molding scheme and molding device for irregular heights.

[0005] The embodiments of the present invention are achieved through the following technical solutions:

[0006] On one hand, the present invention provides a method for one-time casting and molding of irregularly shaped high piers, comprising the following steps:

[0007] The casting mold is constructed, which includes the pier body mold, two sets of ventral arch molds and the cap beam mold arranged sequentially from bottom to top; the two sets of ventral arch molds are supported above the pier body mold and form a Y-shaped structure with the pier body mold;

[0008] For pier body casting, grout is injected into the pier body mold through the skylight at the top of the pier body mold located between the two sets of spandrel arch molds until the pier body casting is completed.

[0009] For the casting of the ventral arch and cap beam, grout is injected into the two sets of ventral arch molds through the openings at the top, and the casting of the ventral arch and cap beam is completed sequentially from bottom to top.

[0010] Furthermore, before the pier body is poured, a set of construction platforms is erected above the pier body mold and around the cap beam mold. Each set of construction platforms is equipped with a movable concrete hopper to introduce slurry into the mold.

[0011] Furthermore, during the pier pouring process, the slurry discharged from the concrete hopper is introduced into the pier mold through a tremie pipe to prevent slurry segregation, and the tremie pipe is gradually lifted upward by a winch.

[0012] Furthermore, during the casting of the ventral arch and the cap beam, two sets of concrete hoppers are set on the construction platform located around the cap beam mold. Each set of concrete hoppers is located above a set of ventral arch molds, and the lower end of each set of concrete hoppers is connected to a set of tremie pipes extending into the ventral arch mold.

[0013] Furthermore, during the pier body pouring process, the skylight is immediately closed after the pier body is poured.

[0014] Furthermore, during the pier body pouring and the spandrel arch and cap beam pouring steps, the concrete inside the mold needs to be vibrated. Vibration methods include internal vibration of the mold and / or setting a vibrator on the outer wall of the mold.

[0015] Furthermore, during the pier body pouring process, after the pier body is poured, the skylight at the top of the pier body mold and the discharge port of the tremie pipe are sealed, and the concrete hopper and tremie pipe are hoisted to the construction platform located around the cap beam.

[0016] On the other hand, the present invention provides a one-time casting and molding device for irregularly shaped high piers, the molding device comprising:

[0017] Pier mold;

[0018] Two sets of arch molds are installed on the upper part of the pier body mold, forming a Y-shaped structure with the pier body mold; and

[0019] The cap beam mold is installed on the upper end of the two sets of belly arch molds, and its lower end is connected to the two sets of belly arch molds; the cap beam mold is provided with reserved holes for threading wire ropes for connecting the winch and the drum.

[0020] Furthermore, the casting mold and construction platform are supported on a movable support pad by temporary support columns, wherein the support pad is placed on the ground.

[0021] Furthermore, an insertable vibrator is provided inside the pier body mold, and several attached vibrators are evenly spaced on the outer wall of the pier body mold.

[0022] Furthermore, a first construction platform is provided above the pier body mold, and a second construction platform is provided around the cap beam mold; wherein, a conduit is connected to the concrete hopper located on the first construction platform, and the conduit is connected to a truck pump for grouting, and the conduit is installed on the first construction platform and the second construction platform.

[0023] The technical solutions of the embodiments of the present invention have at least the following advantages and beneficial effects:

[0024] 1. The pier body mold, two sets of spandrel arch molds and cap beam molds are erected in one go, saving the overall mold erection time; in addition, due to the overall support of the molds, there is no need to wait for the pier body to be formed and the molds to be removed before the spandrel arch and cap beam construction is carried out, saving the construction period;

[0025] 2. First, pour the pier body mold. The pier body mold is vertical and has a skylight reserved at the top to facilitate grouting and vibration operation inside the pier body mold, facilitate the insertion and lifting of the tremie pipe, avoid concrete segregation, and reduce the difficulty of pier body pouring.

[0026] 3. After the pier body formwork is poured, the skylight is closed, and the spandrel arch and cap beam can be poured. The two sets of spandrel arches and cap beams are poured at one time, saving the construction period and reducing the construction difficulty. Attached Figure Description

[0027] Figure 1 This is a flowchart of the one-time casting and molding method for irregularly shaped high piers according to the present invention;

[0028] Figure 2 This is a front view of the non-standard high pier casting and molding device of the present invention;

[0029] Figure 3 This is a side view of the non-standard high pier casting and molding device of the present invention;

[0030] Icons: 1-Casting mold, 10-Pier mold, 100-Skylight, 11-Arch mold, 12-Cap beam mold, 13-Temporary support column, 130-Support pad, 2-Construction platform, 20-First construction platform, 21-Second construction platform, 210-Reserved hole, 22-Concrete hopper, 23-Stringer, 24-Winder, 25-Guardrail, 30-Conduit pipe, 31-Vehicle pump, 40-Immersion vibrator, 41-Attached vibrator. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0032] Example 1:

[0033] Reference Figures 1 to 3 This embodiment provides a one-time casting and forming device for irregularly shaped high piers, including a casting mold 1 and a construction platform 2.

[0034] The casting mold 1 includes a pier body mold 10, two sets of arch molds 11 and a cap beam mold 12 arranged from bottom to top. The two sets of arch molds 11 are installed at the top of the pier body mold 10 in an oblique bracing manner. The two sets of arch molds 11 and the pier body mold 10 form a Y-shaped structure. The cap beam mold 12 is supported on the top of the two sets of arch molds 11.

[0035] Reference Figure 1 and Figure 2 The casting mold 1 is also equipped with two sets of construction platforms 2, namely the first construction platform 20 located at the top of the pier body mold 10 and around the two sets of arch molds 11, and the second construction platform 21 located at the top of the two sets of arch molds 11 and around the cap beam mold 12. Both sets of construction platforms 2 are equipped with movable concrete hoppers 22. The concrete hoppers 22 are trolley-type structures that can move freely and have their own braking and fixing systems, which facilitates fixing the concrete hoppers 22 during casting.

[0036] Reference Figure 1 Each set of construction platform 2 is equipped with a set of guardrails 25. The first construction platform 20 and the second construction platform 21 are supported on both sides by temporary support columns 13. The lower end of the temporary support column 13 is equipped with a support pad 130 placed on the ground to increase the contact area with the ground and make the support structure more stable.

[0037] In addition, refer to Figure 1 and Figure 2 The upper end of the pier body mold 10 is provided with a skylight 100, which is located between the lower end faces of the two sets of ventral arch molds 11. The skylight 100 is used to inject grout into the pier body mold 10.

[0038] Reference Figure 1 A set of shunt tubes 23 is suspended inside the pier body mold 10. The shunt tubes 23 are composed of several sets of shunt tube sections connected together and can be disassembled independently. The upper end of the shunt tubes 23 is suspended by a set of steel wire ropes. The upper end of the steel wire ropes passes through the skylight 100 and the reserved hole 210 located on the second construction platform 21. A winch 24 is set on the second construction platform 21. The upper end of the steel wire rope is connected to the winch 24, and the winch 24 drives the shunt tubes 23 to be lifted. When pouring the pier body, the shunt tubes 23 are first lowered into the pier body mold 10. During the grouting process, the winch 24 gradually lifts the shunt tubes 23 upwards, so that the height difference between the shunt tubes 23 and the concrete surface inside the pier body mold 10 is always within a suitable range, so as to avoid segregation of the concrete grout during the falling process.

[0039] The diameter of the reserved hole 210 is preferably a small hole of 5*5cm, which is convenient to close in time after construction is completed.

[0040] A cover plate is installed on the skylight 100. After the pier body is poured, the skylight 100 can be closed to complete the pier body pouring.

[0041] In addition, refer to Figure 2 The casting mold 1 is also equipped with a guide pipe 30, which is fixed on the first construction platform 20 and the second construction platform 21. The lower end of the guide pipe 30 extends to the tremie pipe 23 of the first construction platform 20. When the pier mold 10 is grouted, the upper end of the guide pipe 30 is connected to the truck pump 31. The guide pipe 30 guides the grout into the tremie pipe 23, avoiding interference from the grouting of the pier mold 10 caused by the arch mold 11, the cap beam mold 12 and the second construction platform 21 above the pier mold 10.

[0042] Reference Figure 1 and Figure 2 An insert vibrator 40 is installed inside the pier body mold 10. Several sets of attached vibrators 41 are evenly arranged on the outer side wall of the pier body mold 10. When in use, the attached vibrator 41 is the main vibrator and the insert vibrator 40 is used for auxiliary vibration.

[0043] Reference Figure 1 The second construction platform 21 is equipped with two sets of concrete hoppers 22. Each set of concrete hoppers 22 has a set of shunt tubes 23 suspended at the lower end. The lower ends of the two sets of shunt tubes 23 extend into the upper opening of a set of arch molds 11.

[0044] Example 2:

[0045] Reference Figures 1 to 3 This embodiment provides a method for one-time casting and molding of irregularly shaped high piers, including the following steps:

[0046] S1. Construct casting mold 1;

[0047] S2. Casting the pier body;

[0048] S3. Casting of the spandrel arch and cap beam;

[0049] Reference Figure 1 In step S1, the casting mold 1 includes a pier body mold 10, two sets of arch molds 11 and a cap beam mold 12 arranged sequentially from bottom to top. The lower ends of the two sets of arch molds 11 are supported above the pier body mold 10 and form a Y-shaped structure with the pier body mold 10. The cap beam mold 12 is supported above the two sets of arch molds 11. When setting up the casting mold 1, the pier body mold 10, the two sets of arch molds 11 and the cap beam mold 12 are set up sequentially from top to bottom.

[0050] Reference Figure 1In step S2, when pouring the pier body, grout is first injected into the pier body mold 10 through the skylight 100 at the upper end of the pier body mold 10 located between the two sets of arch molds 11. The concrete grout is introduced into the pier body mold 10 along the tremie pipe 23 until the pier body is poured. During the process, the grout discharged from the concrete hopper 22 is introduced into the pier body mold 10 through the tremie pipe 23, and the tremie pipe 23 is gradually lifted upward by the winch 24 so that the lower end of the tremie pipe 23 is kept at a suitable height with the concrete surface in the pier body mold 10 to avoid grout segregation.

[0051] During the casting of the arch and cap beam in step S3, grout is injected into the two sets of arch molds 11 through the upper openings of the two sets of arch molds 11, that is, grout is injected into the two sets of concrete hoppers 22 through the truck pump 31. The concrete grout flows into the arch mold 11 along the tremie pipe 23 below the concrete hopper 22, and the casting of the arch and cap beam is completed from bottom to top.

[0052] In step S2 of pier body pouring, the skylight 100 is closed immediately after the pier body is poured; after the pier body is poured, the skylight 100 at the top of the pier body mold 10 and the discharge port of the tremie pipe 23 are closed, and the concrete hopper 22 and tremie pipe 23 on the first construction platform 20 are hoisted to the second construction platform 21 located around the cap beam mold 21.

[0053] In addition, during the pier body pouring step S2 and the spandrel arch and cap beam pouring step S3, the concrete inside the mold needs to be vibrated.

[0054] In the one-time casting method for irregular high piers of the present invention, the irregular pier column can be formed in one go through two casting stages: the first casting in the pier body mold 10 and the second casting in the arch mold 11 and the cap beam mold 12. There is no need to wait for the pier body to be formed before casting the arch and cap beam, which greatly shortens the construction cycle.

[0055] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for one-time casting and molding of irregularly shaped high piers, characterized in that, Includes the following steps: The casting mold (1) is constructed. The casting mold (1) includes a pier body mold (10), two sets of ventral arch molds (11) and a cap beam mold (12) arranged from bottom to top. The two sets of ventral arch molds (11) are supported above the pier body mold (10) and form a Y-shaped structure with the pier body mold (10). For pier body casting, grout is injected into the pier body mold (10) at the top of the pier body mold (10) located between the two sets of ventral arch molds (11) until the pier body casting is completed; For the casting of the ventral arch and cap beam, grout is injected into the two sets of ventral arch molds (11) through the opening at the upper end of the two sets of ventral arch molds (11), and the casting of the ventral arch and cap beam is completed from bottom to top. Before the pier body is poured, a set of construction platforms (2) are erected above the pier body mold (10) and around the cap beam mold (12). Each set of construction platforms (2) is equipped with a movable concrete hopper (22) to introduce slurry into the mold. During the pier pouring process, the grout discharged from the concrete hopper (22) is introduced into the pier mold (10) through the chute (23). The upper end of the chute (23) is suspended by a set of steel wire ropes. The upper end of the steel wire ropes passes through the skylight (100) and the reserved hole (210) on the second construction platform (21). A winch (24) is installed on the second construction platform (21). The upper end of the steel wire rope is connected to the winch (24). The winch (24) drives the chute (23) to be lifted. When pouring the pier, the chute (23) is first lowered into the pier mold (10). During the grouting process, the winch (24) is used to gradually lift the chute (23) upwards, so that the height difference between the chute (23) and the concrete surface in the pier mold (10) is always within a suitable range, so as to avoid segregation of the concrete grout during the falling process. In the process of casting the ventral arch and the cap beam, two sets of concrete hoppers (22) are set on the construction platform (2) located around the cap beam mold (12). Each set of concrete hoppers (22) is located above a set of ventral arch molds (11), and the lower end of each set of concrete hoppers (22) is connected to a set of tremie pipes (23) extending into the ventral arch mold (11). During the pier body pouring process, the skylight (100) is immediately closed after the pier body is poured.

2. The method for one-time casting and molding of irregularly shaped high piers according to claim 1, characterized in that, During the pier body pouring and the spandrel arch and cap beam pouring steps, the concrete inside the mold needs to be vibrated. Vibration methods include internal vibration of the mold and / or setting a vibrator on the outer wall of the mold.

3. The method for one-time casting and molding of irregularly shaped high piers according to claim 1, characterized in that, During the pier body pouring process, after the pier body is poured, the skylight (100) at the top of the pier body mold (10) and the discharge port of the tremie pipe (23) are closed, and the concrete hopper (22) and tremie pipe (23) are hoisted to the construction platform (2) located around the cap beam.

4. A molding apparatus using the one-time casting molding method for irregularly shaped high piers as described in any one of claims 1 to 3, characterized in that, The device includes: Pier body mold (10); Two sets of arch molds (11) are installed on the upper end of the pier body mold (10), forming a Y-shaped structure with the pier body mold (10); and The cap beam mold (12) is installed on the upper end of the two sets of belly arch molds (11), and the lower end is connected to the two sets of belly arch molds (11); the cap beam mold (12) is provided with a reserved hole (210) for threading the wire rope for connecting the winch (24) and the drum (23).

5. The molding apparatus according to claim 4, characterized in that, The casting mold (1) and construction platform (2) are supported on a movable support pad (130) by temporary support columns (13), wherein the support pad (130) is placed on the ground.

6. The molding apparatus according to claim 4, characterized in that, A first construction platform (20) is provided above the pier body mold (10), and a second construction platform (21) is provided around the cap beam mold (12); wherein, a conduit (30) is connected to the concrete hopper (22) located on the first construction platform (20), and the conduit (30) is connected to the truck pump (31) used for grouting, and the conduit (30) is installed on the first construction platform (20) and the second construction platform (21).

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