Prefabrication production method of long and short line combination of floating UHPC buoy segments

Abstract

The invention discloses a prefabrication production method for long and short line combination of floating UHPC floating body segments, including pouring a foundation and installing a slide rail on the foundation; laying a bottom mold on the slide rail and performing a leveling operation; binding and forming a steel skeleton as a whole, and hoisting it to the bottom mold, and then adjusting the position; installing a mobile end mold and fixing a prestressed pipe on the mobile end mold and the steel skeleton; installing an outer mold and performing a mold closing operation with the mobile end mold; operating a hydraulic inner mold to move to a specified position in the inner cavity of the floating body segment; pouring concrete for the floating body segment; maintaining the floating body segment; removing the mobile end mold, the outer mold and the hydraulic inner mold; moving the mobile end mold, the outer mold and the hydraulic inner mold forward by one station; disengaging the floating body segment n-1 from the already poured floating body segment n, and then hoisting the floating body segment n-1 from the bottom mold; repeating the cycle until the production target is achieved. The invention can ensure that the matching surface will not be damaged when the floating body segments are separated, and lossless separation is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of a core buoy of a floating wind turbine generator set, and in particular to a prefabrication production method for combining long and short lines and matching floating UHPC buoy segments. Background Art

[0002] The floating wind turbine ultra-high strength concrete (Uhpc) buoy segment is the structural unit of the floating foundation buoy. Its prefabrication production method is similar to that of the bridge segment production. The bridge segment production is divided into two matching methods: short-line matching production and long-line matching production.

[0003] The general process of the short-line matching production method is as follows: n-segment steel skeleton binding, mold installation inspection, steel skeleton mold placement, concrete pouring and vibration → n-segment mold removal (side mold + inner mold) and maintenance → n-segment components move forward one station → use the prefabricated n segments as one side end mold to match and produce the next segment n+1 → produce each segment one by one, the poured matching segment and bottom mold are moved, and the pouring station and one side end mold are fixed. The main features of the short-line matching production method are as follows Figure 2 shown.

[0004] The general process of the long-line matching production method is as follows: n-segment steel skeleton binding, mold installation inspection, steel skeleton mold placement, concrete pouring and vibration → n-segment mold removal (side mold + inner mold + mobile end mold) and maintenance → side mold, inner mold and mobile end mold move forward one station → use the prefabricated n segments as one side end mold to match and produce the next segment n+1 → produce each pipe segment one by one in this way, the poured matching segment and the bottom mold are fixed, and the pouring station and one side end mold are moved. This is the main feature of the long-line matching production method, as follows Figure 3 shown.

[0005] Compared with the short-line method, the long-line matching production method is easier to ensure the linear control of the components. The monitoring, measurement and adjustment in the production stage are convenient to operate and the steps are simple, which is relatively easy to implement.

[0006] However, the end face size of the floating body segment of the floating wind turbine is huge (greater than 12m×6m), and dozens of prestressed pipes and conical embedded casings are arranged on the end face, as well as more than 30 shear key grooves and annular waterproof grooves. For the non-planar structure with dense end faces, the traditional long-line matching production method faces great difficulties when the matching surface (when the floating body segment n is being prefabricated, the surface between the previously prefabricated floating body segment n-1 and the floating body segment n) is disengaged and separated. It is difficult to ensure that the matching surface will not be damaged when the floating body segments are separated, and it is difficult to achieve lossless separation. Summary of the invention

[0007] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a floating (wind turbine) Uhpc floating body segment long and short line combined matching prefabrication production method, which can ensure that the matching surface will not be damaged when the floating body segments are separated, thereby achieving lossless separation.

[0008] To achieve the above purpose, the technical solution provided by the present invention is:

[0009] The floating UHPC buoy segment long and short line combined matching prefabrication production method includes

[0010] pour the foundation and install the rails on it;

[0011] Lay the bottom mold on the slide rails along its entire length and perform leveling operations;

[0012] Tie the steel bar skeleton as a whole and hoist it onto the bottom formwork, then adjust its position;

[0013] Install the mobile end formwork and fix the prestressed pipe on the mobile end formwork and the steel frame;

[0014] Install the outer mold, and perform mold closing operation on the installed outer mold and the mobile end mold;

[0015] Operate the hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment, adjust the axis position, and open the hydraulic inner mold;

[0016] With the cooperation of the bottom mold, the mobile end mold, the outer mold and the hydraulic inner mold, the floating body segment concrete is poured;

[0017] Maintaining the floating body segments obtained by pouring concrete;

[0018] Remove the mobile end mold, outer mold and hydraulic inner mold;

[0019] Move the movable end mold, the outer mold and the hydraulic inner mold forward one station, and use the prefabricated floating body segment n as the end mold on one side of the next segment, so as to prepare for matching and producing the next floating body segment n+1;

[0020] The bottom form is pushed to move longitudinally along the foundation by using the hydraulic system, so that the floating body segment n-1 slides longitudinally backward on the foundation for a certain distance, the floating body segment n-1 is separated from the already cast floating body segment n, and then the floating body segment n-1 is lifted off the bottom form;

[0021] Repeat the cycle until the production target is reached.

[0022] Further, pouring the foundation and installing the slide rail on the foundation includes:

[0023] The foundation is first poured to a horizontal position of -0.1m. After the slide rail is installed in place and leveled, a high-strength self-compacting cement-based material is used for secondary pouring and grouting to a position of ±0.000m to fix the slide rail.

[0024] Furthermore, the slide rails include supporting slide rails and guiding slide rails, and the supporting slide rails and guiding slide rails are spaced apart after being installed in place.

[0025] Furthermore, before the mobile end mold is fixed to the steel bar skeleton, an adjustment operation is performed on the mobile end mold, and the adjustment operation includes:

[0026] After controlling the mobile end mold to slide to the preset position, the axis position, verticality and flatness of the mobile end mold are adjusted and reinforced. The flatness of the mobile end mold is controlled within the set range, and then the position and line shape of the prestressed pipe are adjusted.

[0027] Furthermore, after the outer mold and the movable end mold are closed, a mold tightness check is performed between the outer mold, the movable end mold and the matching section (when the float segment n is being prefabricated, the previous prefabricated float segment n-1 is the matching section of the float segment n).

[0028] Furthermore, after the hydraulic inner mold is expanded, a tightness check is performed between the hydraulic inner mold, the movable end mold and the matching section.

[0029] Furthermore, when pouring concrete for the floating body segment, the concrete pouring sequence is: bottom plate - side plates on both sides - top plate; layered material is poured and vibrated, the thickness of each layer does not exceed the height of the vibrator spacing, and the pouring time of the upper and lower layers does not exceed 1 hour; the two side plates are poured alternately and evenly; and finally the top plate is poured.

[0030] Furthermore, during the pause process of alternately pouring the two side panels, an atomizer is turned on for moisturizing.

[0031] Furthermore, the floating body segments obtained by pouring concrete are maintained, including:

[0032] After pouring, the pouring mouth is covered with film, and a spray head is hung diagonally to maintain the ambient humidity. After standing for 2 days, the floating body segment is covered with a steam-curing cloth, and then the steam pipe is opened to enter the steam curing stage. In the early stage, the steam valve opening is kept small. After 1 hour of constant temperature, the steam opening is adjusted to control the ambient temperature rise rate of 5 to 10°C / h, which shall not exceed 10°C / h. When the temperature rises to 60 to 70°C, the steam valve is controlled to start the constant temperature stage and constant temperature curing is carried out for 3 days. During this stage, the air supply is uniform to ensure high temperature and high humidity. After the steam curing is completed, the temperature is gradually reduced at a rate of 5 to 15°C / h. When the temperature difference between the surface of the floating body segment and the environment is 10 to 20°C, the steam curing is stopped and natural curing is carried out. The surface of the floating body segment is kept moist to a level not less than 70% of the standard strength of the concrete strength of the specimen cured under the same conditions at 28 days, and for not less than 14 days.

[0033] Compared with the existing technology, the principle and advantages of this solution are as follows:

[0034] A high-precision slide rail is installed between the bottom of the bottom mold and the foundation, so that the bottom mold and the cast floating body segments can slide with high precision, changing the existing long-line matching prefabrication method, achieving lossless separation of matching surfaces, and ensuring that the end shear keys, waterproof sealing grooves, and tapered holes are not damaged, fully ensuring the safety of the structure. At the same time, it can fully combine the advantages of the long-short line matching method, improve the utilization efficiency of the working surface and ensure the smoothness of the line shape.

[0035] In addition, the high-precision slide rails installed on the foundation enable the bottom mold to slide longitudinally on the slide rails, and the bottom mold can be recycled. Compared with the traditional long-line bottom mold plate that needs to cover the entire pedestal, it can greatly save the number of bottom mold processing and save costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the services required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0037] Figure 1 It is a principle flow chart of the long and short line combined matching prefabrication production method of the floating Uhpc buoy segment of the present invention;

[0038] Figure 2 It is a schematic diagram of the production matching of the short-line method;

[0039] Figure 3 It is a schematic diagram of the production matching of the long-line method;

[0040] Figure 4 It is a schematic diagram of pouring the foundation and installing the slide rail on the foundation in the prefabrication production method of the floating Uhpc buoy segment long and short line combination matching of the present invention;

[0041] Figure 5 It is a schematic diagram of laying the bottom mold on the slide rail in the prefabrication production method of the floating Uhpc floating body segment long and short line combination matching of the present invention;

[0042] Figure 6 This is a schematic diagram after the bottom mold, mobile end mold, outer mold and hydraulic inner mold are installed;

[0043] Figure 7 Schematic diagram for dismantling the mobile end mold, the outer mold and the hydraulic inner mold;

[0044] Figure 8It is a schematic diagram of the outer mold, hydraulic inner mold and movable end mold moving forward one station;

[0045] Fig. 9 This is a schematic diagram of using a hydraulic system to push the bottom formwork to move longitudinally along the concrete foundation. DETAILED DESCRIPTION

[0046] The present invention will be further described below in conjunction with specific embodiments:

[0047] like Figure 1 As shown, the floating (wind turbine) Uhpc floating body segment long and short line matching prefabrication production method described in this embodiment includes the following steps:

[0048] S1. Pour the foundation and install the slide rails on it. The process is as follows:

[0049] The foundation is poured to -0.1m for the first time. After the support rails and guide rails are installed and accurately leveled, high-strength self-compacting cement-based materials are used for secondary pouring and grouting to ±0.000m to fix the support rails and guide rails. Figure 4 As shown in the figure, the fixed support rails and guide rails are distributed at intervals.

[0050] S2. Lay the bottom mold on the slide rail and perform leveling operations to ensure the installation quality of the bottom mold. Figure 5 shown.

[0051] S3. Use the special tooling for steel frame binding to bind the steel frame as a whole. The tooling should have the functions of forming the steel frame, limiting the inner and outer dimensions of the steel frame, positioning the longitudinal main bars and circumferential distribution bars of the steel frame, and positioning the prestressed channel. After the steel frame is bound, it is hoisted onto the bottom formwork as a whole, and the position of the steel frame is adjusted.

[0052] S4. The hydraulic sliding device of the mobile end mold is used to control the mobile end mold to slide to the preset position and fine-tune and fix the axis position, verticality and flatness of the mobile end mold. The flatness of the mobile end mold is controlled within ±0.5mm. Then the position and line shape of the prestressed pipe are adjusted. After the adjustment is completed, the prestressed pipe is fixed to the mobile end mold and the steel frame.

[0053] S5. After installing the outer mold and closing the installed outer mold with the movable end mold, check the tightness of the closing between the outer mold, the movable end mold and the matching section (when prefabricating floating body segment n, the previous prefabricated floating body segment n-1 is the matching section of floating body segment n) to prevent dripping of concrete slurry during pouring.

[0054] S6. Operate the hydraulic inner mold to move to the specified position in the inner cavity of the floating body segment, adjust the axis position, and open the hydraulic inner mold. The hydraulic inner mold should not be positioned and fixed by the end mold to prevent the hydraulic inner mold from being disturbed during concrete pouring and affecting the end mold. After the hydraulic inner mold is installed, check the gap between the inner membrane and the end mold and the matching section to ensure its tightness and prevent leakage. Figure 6 shown.

[0055] S7, pouring concrete of the floating body segment with the cooperation of the bottom mold, the movable end mold, the outer mold and the hydraulic inner mold;

[0056] In this step, concrete pouring follows the principle of "from the middle to both ends, symmetrical, and horizontally layered". The order of concrete pouring is: bottom plate - side plates on both sides - top plate; layered material feeding and vibrating, the thickness of each layer should not exceed the height of the vibrator spacing, and the pouring time of the upper and lower layers should not exceed 1 hour. The two side plates are poured alternately and evenly. During the pauses of alternating pouring, turn on the atomizer to keep it moist. Finally, pour the top plate. It must be ensured that the top plate concrete is poured before the side plate concrete begins to set, and it must be leveled and finished in time.

[0057] S8. Maintaining the floating body segments obtained by pouring concrete, including:

[0058] After pouring, the pouring mouth is covered with film, and a spray head is hung diagonally to maintain the ambient humidity. After standing for 2 days, the floating body segment is covered with a steam-curing cloth, and then the steam pipe is opened to enter the steam curing stage. In the early stage, the steam valve opening is kept small. After 1 hour of constant temperature, the steam opening is adjusted to control the ambient temperature rise rate of 5 to 10°C / h, which shall not exceed 10°C / h. When the temperature rises to 60 to 70°C, the steam valve is controlled to start the constant temperature stage and constant temperature curing is carried out for 3 days. During this stage, the air supply is uniform to ensure high temperature and high humidity. After the steam curing is completed, the temperature is gradually reduced at a rate of 5 to 15°C / h. When the temperature difference between the surface of the floating body segment and the environment is 10 to 20°C, the steam curing is stopped and natural curing is carried out. The surface of the floating body segment is kept moist to a level not less than 70% of the standard strength of the concrete strength of the specimen cured under the same conditions at 28 days, and for not less than 14 days.

[0059] S9, remove the mobile end mold, the outer mold and the hydraulic inner mold, such as Figure 7 shown.

[0060] S10, move the movable end mold, the outer mold and the hydraulic inner mold forward one station, use the prefabricated floating body segment n as the side end mold of the next segment, and prepare to match and produce the next floating body segment n+1, such as Figure 8 shown.

[0061] S11. Use the hydraulic system to push the bottom formwork to move longitudinally along the foundation, so that the floating body segment n-1 slides longitudinally backward 500 mm on the foundation, separates the floating body segment n-1 from the already cast floating body segment n, and then lifts the floating body segment n-1 off the bottom formwork. Fig. 9 shown.

[0062] S12. Repeat S3-S11 until the production target is achieved.

[0063] This embodiment installs a high-precision slide rail between the bottom of the bottom mold and the foundation, so that the bottom mold and the cast floating body segment can achieve high-precision sliding, which changes the existing long-line matching prefabrication method, achieves lossless separation of the matching surface, ensures that the end shear key, waterproof sealing groove, and conical hole are not damaged, fully guarantees the safety of the structure, and can fully combine the advantages of the long-short line matching method, improve the efficiency of working surface utilization and ensure the smoothness of the line shape. In addition, the high-precision slide rail set on the foundation allows the bottom mold to slide longitudinally on the slide rail, and the bottom mold can be recycled. Compared with the traditional long-line bottom mold that needs to be covered with a pedestal, it can save a lot of bottom mold processing and save costs.

[0064] The embodiments described above are only preferred embodiments of the present invention and are not intended to limit the scope of implementation of the present invention. Therefore, all changes made according to the shape and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. The floating UHPC buoy segment long and short line matching prefabrication production method is characterized by: This includes pouring the foundation and installing the slide rails on the foundation; Lay the bottom mold on the slide rails along its entire length and perform leveling operations; Tie the steel bar skeleton as a whole and hoist it onto the bottom formwork, then adjust its position; Install the mobile end formwork and fix the prestressed pipe on the mobile end formwork and the steel frame; Install the outer mold, and perform mold closing operation on the installed outer mold and the mobile end mold; Operate the hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment, adjust the axis position, and open the hydraulic inner mold; With the cooperation of the bottom mold, the mobile end mold, the outer mold and the hydraulic inner mold, the floating body segment concrete is poured; Maintaining the floating body segments obtained by pouring concrete; Remove the mobile end mold, outer mold and hydraulic inner mold; Move the movable end mold, the outer mold and the hydraulic inner mold forward one station, and use the prefabricated floating body segment n as the end mold on one side of the next segment, so as to prepare for matching and producing the next floating body segment n+1; The bottom form is pushed to move longitudinally along the foundation by using the hydraulic system, so that the floating body segment n-1 slides longitudinally backward on the foundation for a certain distance, the floating body segment n-1 is separated from the already cast floating body segment n, and then the floating body segment n-1 is lifted off the bottom form; Repeat the cycle until the production target is reached.

2. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 1 is characterized in that: Concrete the foundation and install the rails on it, including: The foundation is first poured to a horizontal position of -0.1m. After the slide rail is installed in place and leveled, a high-strength self-compacting cement-based material is used for secondary pouring and grouting to a position of ±0.000m to fix the slide rail.

3. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 2 is characterized in that: The slide rails include supporting slide rails and guiding slide rails, which are spaced apart after being installed in place.

4. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 1 is characterized in that: Before the mobile end mold is fixed on the steel bar skeleton, the mobile end mold is adjusted. The adjustment operation includes: After controlling the mobile end mold to slide to the preset position, the axis position, verticality and flatness of the mobile end mold are adjusted and reinforced. The flatness of the mobile end mold is controlled within the set range, and then the position and line shape of the prestressed pipe are adjusted.

5. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 1 is characterized in that: After the outer mold and the movable end mold are closed, the tightness of the closing between the outer mold, the movable end mold and the matching section is checked.

6. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 1 is characterized in that: After the hydraulic inner mold is expanded, a tightness check is performed between the hydraulic inner mold, the movable end mold and the matching section.

7. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 1 is characterized in that: When pouring concrete for the floating body segment, the concrete pouring sequence is: bottom plate - side plates on both sides - top plate; pouring and vibrating in layers, the thickness of each layer shall not exceed the height of the vibrator spacing, and the pouring time of the upper and lower layers shall not exceed 1 hour; the two side plates shall be poured alternately and evenly; finally, the top plate shall be poured.

8. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 7 is characterized in that: During the pause process of alternately pouring the two side panels, the atomizer is turned on for moisturizing.

9. The long and short line matching prefabrication production method of floating UHPC buoy segments according to claim 1 is characterized in that: Maintenance of the floating body segments obtained by concrete pouring, including: After pouring, the pouring mouth is covered with film, and a spray head is hung diagonally to maintain the ambient humidity. After standing for 2 days, the floating body segment is covered with a steam-curing cloth, and then the steam pipe is opened to enter the steam curing stage. In the early stage, the steam valve opening is kept small. After 1 hour of constant temperature, the steam opening is adjusted to control the ambient temperature rise rate of 5 to 10°C / h, which shall not exceed 10°C / h. When the temperature rises to 60 to 70°C, the steam valve is controlled to start the constant temperature stage and constant temperature curing is carried out for 3 days. During this stage, the air supply is uniform to ensure high temperature and high humidity. After the steam curing is completed, the temperature is gradually reduced at a rate of 5 to 15°C / h. When the temperature difference between the surface of the floating body segment and the environment is 10 to 20°C, the steam curing is stopped and natural curing is carried out. The surface of the floating body segment is kept moist to a level not less than 70% of the standard strength of the concrete strength of the specimen cured under the same conditions at 28 days, and for not less than 14 days.

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