Method and system for lining concrete arch walls

Abstract

The application relates to the construction field and provides a method and system for lining concrete of an arch wall. The method for lining concrete of the arch wall can improve the construction quality of subsequent processes and the overall performance of a structure; effectively improves the waterproof performance of the structure, reduces the possibility of water seepage; guarantees the thickness of a protective layer of steel bars, helps to improve the stability and durability of the structure; ensures the accurate position of a pre-buried channel, facilitates subsequent pipeline installation and maintenance work; makes a formwork system more stable, facilitates demolding, and improves construction efficiency; improves the uniformity of pouring, shortens the construction time, and avoids damage to a concrete structure caused by early demolding. Therefore, the method for lining concrete of the arch wall of the application embodiment realizes multiple technical effects of improving construction efficiency, guaranteeing engineering quality, enhancing structural stability and durability, and the like through accurate process control and innovative construction technology.

Description

Technical Field

[0001] This invention relates to the field of construction and provides a method and system for lining concrete for arch walls. Background Technology

[0002] In related technologies, lining trolleys are mainly used for concrete pouring in applications such as tunnels, water diversion tunnels, and secondary lining.

[0003] However, in related technologies, lining trolleys are prone to problems during use, such as inaccurate positioning of pre-embedded channels, misalignment at longitudinal construction joints, and grout leakage. During the concrete pouring process on the lining trolley, inadequate concrete compaction can also occur, leading to cavities caused by concrete shrinkage and water loss, thus affecting the quality of the project. Summary of the Invention

[0004] This invention aims to at least solve one of the technical problems existing in related technologies. To this end, this invention proposes a method for lining concrete in arch walls, which can meet the requirements of concrete pouring and vibration processes, and ensure the traceability of the lining concrete pouring process.

[0005] This invention also provides a system for lining concrete arch walls.

[0006] A first aspect of the present invention provides a method for lining concrete in an arch wall, comprising:

[0007] Initial section scanning determines that the actual flatness of the shotcrete is less than or equal to the preset flatness.

[0008] When laying composite waterproof membranes, the overlap width of adjacent composite waterproof membranes is greater than or equal to a preset width value and is staggered from each other by construction joints;

[0009] The reinforcing steel reinforcement is installed with spacers between it and the composite waterproof membrane;

[0010] For the installation and positioning of the pre-embedded channel, bolt positioning holes are uniformly opened at the corresponding parts of the trolley panel. The pre-embedded channel is positioned at the lining steel bar once, positioned at the bolt positioning holes a second time, and finally poured and demolded.

[0011] An assembly trolley is provided with flexible joints along the circumference of the trolley and a V-groove is installed at the front end of the panel of the trolley. The combined end mold and the moving mold are installed on the trolley.

[0012] Concrete pouring and vibration are carried out by pouring concrete window by window, hole by hole, and layer by layer. Grouting holes and venting holes are reserved in the arch, and vibrating rods and vibrators are used together for vibration.

[0013] Demolding of the concrete involves removing the combined end molds to ensure the concrete meets design strength.

[0014] According to the method for arch wall lining concrete provided in the first aspect of the present invention, the flatness of the shotcrete is ensured to meet the preset standard by scanning the initial support section, thereby improving the construction quality of subsequent processes and the overall performance of the structure. The overlap width of the composite waterproof membrane is greater than or equal to the preset width value and is staggered from the construction joint, which effectively improves the waterproof performance of the structure and reduces the possibility of water seepage. The spacer block is set between the lining reinforcement and the composite waterproof membrane to ensure the thickness of the protective layer of the reinforcement, which helps to improve the stability and durability of the structure. The method of primary positioning and secondary positioning is adopted to ensure the accurate position of the pre-embedded channel, which facilitates the subsequent pipeline installation and maintenance work. The circumferential design of the trolley with soft overlap and front V-groove, as well as the application of combined end mold and moving mold, makes the formwork system more stable, facilitates demolding, and improves construction efficiency. The method of pouring window by window, hole by hole, and layer by layer, as well as the design of reserved grouting holes and venting holes, combined with the combined vibration of vibrator and vibrator, not only improves the uniformity of pouring, but also shortens the construction time. When demolding concrete, the combined end formwork is removed to ensure that the concrete reaches the design strength, thus avoiding damage to the concrete structure caused by premature demolding. Therefore, the arch wall lining concrete method of this invention, through precise process control and innovative construction technology, achieves multiple technical effects such as improved construction efficiency, guaranteed project quality, and enhanced structural stability and durability.

[0015] According to an embodiment of the present invention, the initial branch section scanning step includes:

[0016] The actual smoothness of the shotcrete is determined to be less than or equal to L / 20;

[0017] The initial support section was scanned using a laser scanner. The longitudinal spacing of the scanning points was 0.3 meters for the arched section, 0.1 meters for the section without the arch, and 0.2 meters for the circumferential spacing.

[0018] Where L is the distance between two adjacent convex surfaces of the base plane.

[0019] According to one embodiment of the present invention, the step of laying the composite waterproof membrane includes:

[0020] Install a circumferential drainage blind pipe;

[0021] The overlap width of adjacent composite waterproof membranes is greater than or equal to 50 mm;

[0022] The weld width of the composite waterproof membrane is greater than or equal to 15 cm and is staggered from the construction joint by 1.5 to 2 meters.

[0023] According to one embodiment of the present invention, the step of installing the lining reinforcement includes:

[0024] The reinforcement bars are installed in the following order: interlayer positioning bars, outer main bars, outer longitudinal bars, inner main bars, inner longitudinal bars, structural bars, and reinforcement protective layer spacers.

[0025] The pad block is fixed to the lining steel reinforcement.

[0026] According to an embodiment of the present invention, the step of installing and positioning the pre-embedded channel includes:

[0027] Preparations before channel positioning include determining the integrity of the foamed filler in the channel and ensuring that the distance between the end of the channel and the construction joint is greater than or equal to 100 cm.

[0028] The channel is positioned in one go, and the channel anchor rod is welded to the corresponding grounding steel bar. The lap length of the single-sided welding is greater than or equal to 100 mm, the lap length of the double-sided welding is greater than or equal to 55 mm, and the weld thickness is greater than or equal to 4 mm.

[0029] Secondary positioning of the channel involves adjusting the position of the channel through the positioning holes reserved in the trolley panel to make the channel fit tightly against the template.

[0030] The template is retrieved and the fixing points of the channel are refilled with foam filler.

[0031] According to one embodiment of the present invention, the assembly trolley step includes:

[0032] A soft lap joint is provided on the contact surface between the trolley and the poured concrete along the circumference of the trolley.

[0033] A steel plate is installed at the front end of the trolley so that the steel plate, the trolley panel, and the trolley steel end template form a triangular structure.

[0034] A combination of steel mold ends and polymer mold ends is used to prevent grout leakage and mold displacement at the circumferential construction joints.

[0035] The moving mold is hinged to the integral side mold.

[0036] According to one embodiment of the present invention, the concrete pouring and vibration steps include:

[0037] At least five layers of working windows are provided on both sides of the trolley. At least three feed holes and at least two vibration holes are provided in the first four layers of working windows, and at least three vibration windows are provided in the top layer of working windows.

[0038] Vibrate in layers with a vibration interval of 20 to 30 seconds.

[0039] According to one embodiment of the present invention, the concrete demolding step includes:

[0040] Once the concrete pouring is completed and the concrete strength reaches 8 MPa or above, the polymer composite end mold is removed.

[0041] During demolding, the temperature difference between the interior and surface of the concrete, and between the surface and the environment, shall not exceed 20 degrees Celsius, and the temperature difference between the inner and outer surfaces shall not exceed 15 degrees Celsius.

[0042] According to one embodiment of the present invention, after the concrete demolding step, the method further includes:

[0043] Automated spray curing trolleys are used for maintenance.

[0044] A second aspect of the present invention provides a system for lining concrete for an arch wall, including a trolley on which a processor is provided, the processor executing a program to perform the above-described method for lining concrete for an arch wall.

[0045] According to the second aspect of the present invention, the arch wall lining concrete system can automate and intelligentize the above-mentioned arch wall lining concrete method by setting a processor on the trolley and executing the corresponding program. The processor automatically executes each step of the arch wall lining concrete according to the preset program, reducing the uncertainty of manual operation and improving construction accuracy and efficiency. The processor can intelligently adjust construction parameters, such as the flatness of the concrete and the overlap width of the composite waterproofing membrane, based on real-time data and sensor feedback to ensure construction quality. The system can record key data during the construction process, facilitating subsequent analysis and optimization of the construction process, and improving project quality. By connecting with a cloud platform or other remote management system, remote monitoring and management of the construction site can be achieved, enabling timely detection and resolution of problems. The system can be integrated with other construction equipment and systems, such as concrete pouring equipment and vibration equipment, to form a complete intelligent construction system. With the development of construction technology and changes in needs, the system program can be updated and upgraded to adapt to different construction environments and requirements. Through this intelligent arch wall lining concrete system, not only can construction efficiency and quality be improved, but it can also provide construction units with a large amount of real-time data and analysis results, helping them to better grasp the construction progress and quality status, and further improve the level of construction management.

[0046] The above-described one or more technical solutions in the embodiments of the present invention have at least one of the following technical effects:

[0047] According to the method for arch wall lining concrete provided in the first aspect of the present invention, the flatness of the shotcrete is ensured to meet the preset standard by scanning the initial support section, thereby improving the construction quality of subsequent processes and the overall performance of the structure. The overlap width of the composite waterproof membrane is greater than or equal to the preset width value and is staggered from the construction joint, which effectively improves the waterproof performance of the structure and reduces the possibility of water seepage. The spacer block is set between the lining reinforcement and the composite waterproof membrane to ensure the thickness of the protective layer of the reinforcement, which helps to improve the stability and durability of the structure. The method of primary positioning and secondary positioning is adopted to ensure the accurate position of the pre-embedded channel, which facilitates the subsequent pipeline installation and maintenance work. The circumferential design of the trolley with soft overlap and front V-groove, as well as the application of combined end mold and moving mold, makes the formwork system more stable, facilitates demolding, and improves construction efficiency. The method of pouring window by window, hole by hole, and layer by layer, as well as the design of reserved grouting holes and venting holes, combined with the combined vibration of vibrator and vibrator, not only improves the uniformity of pouring, but also shortens the construction time. When demolding concrete, the combined end formwork is removed to ensure that the concrete reaches the design strength, thus avoiding damage to the concrete structure caused by premature demolding. Therefore, the arch wall lining concrete method of this invention, through precise process control and innovative construction technology, achieves multiple technical effects such as improved construction efficiency, guaranteed project quality, and enhanced structural stability and durability.

[0048] Furthermore, the arch wall lining concrete system provided by the second aspect embodiment of the present invention, by setting a processor on the trolley and executing a corresponding program, can realize the automation and intelligence of the above-mentioned arch wall lining concrete method. The processor automatically executes each step of the arch wall lining concrete according to the preset program, reducing the uncertainty of manual operation and improving construction accuracy and efficiency. The processor can intelligently adjust construction parameters, such as the flatness of the concrete and the overlap width of the composite waterproofing board, based on real-time data and sensor feedback, to ensure construction quality. The system can record key data during the construction process, facilitating subsequent analysis and optimization of the construction process, and improving project quality. Through connection with a cloud platform or other remote management system, remote monitoring and management of the construction site can be realized, allowing for timely detection and resolution of problems. The system can be integrated with other construction equipment and systems, such as concrete pouring equipment and vibration equipment, to form a complete intelligent construction system. With the development of construction technology and changes in needs, the system program can be updated and upgraded to adapt to different construction environments and requirements. This intelligent arch wall lining concrete system not only improves construction efficiency and quality, but also provides construction units with a large amount of real-time data and analysis results, helping them to better grasp the construction progress and quality status, and further improve the level of construction management.

[0049] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0051] Figure 1 This is a schematic structural diagram of the installation of the V-groove rubber strip provided in an embodiment of the present invention;

[0052] Figure 2 This is a schematic structural diagram of the combined end mold assembly structure provided in the embodiment of the present invention;

[0053] Figure 3 yes Figure 1 A magnified view of a section at point A in the middle;

[0054] Figure 4 This is a schematic structural diagram of the trolley configuration unfolded according to an embodiment of the present invention.

[0055] Figure label:

[0056] 100. Panel; 102. Embedded waterstop; 104. U-shaped rebar clip; 106. Trolley formwork; 108. Feed hole; 110. Vibration window; 112. Moving mold; 114. Side mold; 116. Spacer block; 118. Polymer end mold. Detailed Implementation

[0057] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0058] In the description of the embodiments of the present invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0059] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention based on the specific circumstances.

[0060] In embodiments of the present invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0061] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0062] like Figures 1 to 4 As shown, a first aspect of the present invention provides a method for lining concrete for an arch wall, comprising:

[0063] Initial section scanning determines that the actual flatness of the shotcrete is less than or equal to the preset flatness.

[0064] When laying composite waterproof membranes, the overlap width of adjacent composite waterproof membranes should be greater than or equal to the preset width value and should be staggered from each other at construction joints.

[0065] When installing the reinforcing steel lining, spacers 116 are placed between the steel reinforcement and the composite waterproof membrane.

[0066] For the installation and positioning of the pre-embedded channel, bolt positioning holes are uniformly opened at the corresponding positions on the trolley panel 100. The pre-embedded channel is positioned at the lining reinforcement in the first position, and then positioned at the bolt positioning holes in the second position before finally being poured and demolded.

[0067] Assembly trolley, soft overlapping parts are set along the circumference of the trolley and V-groove is installed at the front end of the panel 100 of the trolley, and combined end mold and moving mold 112 are installed on the trolley;

[0068] Concrete pouring and vibration are carried out by pouring concrete window by window, hole by hole, and layer by layer. Grouting holes and venting holes are reserved in the arch, and vibrating rods and vibrators are used together for vibration.

[0069] Demolding of concrete and removal of combined end formwork to ensure concrete meets design strength.

[0070] According to the method for arch wall lining concrete provided in the first aspect of the present invention, the flatness of the shotcrete is ensured to meet the preset standard by scanning the initial support section, thereby improving the construction quality of subsequent processes and the overall performance of the structure. The overlap width of the composite waterproof membrane is greater than or equal to the preset width value and is staggered from the construction joint, which effectively improves the waterproof performance of the structure and reduces the possibility of water seepage. The spacer 116 is set between the lining reinforcement and the composite waterproof membrane to ensure the thickness of the protective layer of the reinforcement, which helps to improve the stability and durability of the structure. The method of primary positioning and secondary positioning is adopted to ensure the accurate position of the pre-embedded channel, which facilitates the subsequent pipe installation and maintenance work. The circumferential design of the trolley with soft overlap and front V-groove, as well as the application of combined end mold and moving mold 112, makes the formwork system more stable, facilitates demolding, and improves construction efficiency. The method of pouring window by window, hole by hole, and layer by layer, as well as the design of reserved grouting holes and venting holes, combined with the combined vibration of vibrator and vibrator, not only improves the uniformity of pouring, but also shortens the construction time. When demolding concrete, the combined end formwork is removed to ensure that the concrete reaches the design strength, thus avoiding damage to the concrete structure caused by premature demolding. Therefore, the arch wall lining concrete method of this invention, through precise process control and innovative construction technology, achieves multiple technical effects such as improved construction efficiency, guaranteed project quality, and enhanced structural stability and durability.

[0071] The initial support section scanning step involves using scanning equipment to inspect the cross-section of the shotcrete to ensure that its actual flatness meets the preset standards required by the project. This process is a crucial step in quality control, helping to ensure the accuracy of subsequent construction and the uniformity of the structure.

[0072] During the installation of the composite waterproofing membrane, the membrane is laid according to the design requirements, ensuring that the overlap width between adjacent membranes meets or exceeds the preset minimum width value. Furthermore, to improve waterproofing, the construction joints and the joints of the composite waterproofing membrane are staggered to prevent moisture penetration through the joints.

[0073] During the installation of the reinforcing steel lining, spacers 116 need to be placed between the reinforcing steel and the composite waterproof membrane to maintain an appropriate distance and protective layer thickness, which is crucial for the stability and durability of the structure.

[0074] In the installation and positioning of the pre-embedded channel, a two-stage positioning method is used. First, the channel is initially positioned on the reinforcing steel lining; then, it is positioned a second time into the bolt positioning holes on the trolley panel 100. This method ensures the precise position of the pre-embedded channel, facilitating the subsequent installation of pipelines and other facilities.

[0075] In the assembly trolley step, the assembly of the trolley includes setting soft overlaps along the circumferential direction to reduce structural stress concentration; installing V-grooves at the front end of the trolley panel 100 to enhance structural stability; and installing combined end molds and moving molds 112 on the trolley, which are used to form the shape of the concrete structure.

[0076] During the concrete pouring and vibration process, the concrete is poured window by window, hole by hole, and layer by layer to ensure the uniformity and density of the structure. Grouting holes and venting holes are pre-reserved in the arch to allow air and excess moisture to escape during pouring. Simultaneously, a vibrator and a compactor are used for combined vibration to further enhance the concrete's density.

[0077] In the concrete demolding process, after the concrete reaches its design strength, the combined end formwork is removed, completing the demolding process. This step requires strict control to ensure the quality of the concrete structure.

[0078] Overall, this method of lining arch walls with concrete, through precise construction steps and strict quality control, achieves structural stability, durability, and waterproof performance, thereby improving the overall quality of the project.

[0079] According to an embodiment of the present invention, the step of initial branch section scanning includes:

[0080] The actual smoothness of the shotcrete is determined to be less than or equal to L / 20;

[0081] The initial support section was scanned using a laser scanner. The longitudinal spacing of the scanning points was 0.3 meters for the arched section, 0.1 meters for the section without the arch, and 0.2 meters for the circumferential spacing. Where L is the distance between two adjacent convex surfaces of the base.

[0082] Specifically, before installing the geotextile, the flatness of the shotcrete should be checked first. Uneven areas should be leveled or reinforced with additional shotcrete to ensure that the flatness D of the shotcrete is less than or equal to L / 20 (D is the depth of indentation between two adjacent convex surfaces of the initial support base, and L is the distance between two adjacent convex surfaces of the base, with L = 1 meter). Exposed anchor bolt heads, rebar heads, wires, etc., should be cut off. Then, a 3D laser scanner should be used to scan the initial support section. The longitudinal spacing of the scanning points is 0.3 meters for sections with arches and 0.1 meters for sections without arches, and the circumferential spacing is 0.2 meters. Any under-excavation should be dealt with promptly, and the amount of lining concrete should be calculated based on the scanned section.

[0083] According to one embodiment of the present invention, the steps of laying the composite waterproof membrane include:

[0084] Install a circumferential drainage blind pipe;

[0085] The overlap width of adjacent composite waterproof membranes is greater than or equal to 50 mm;

[0086] The weld width of the composite waterproof membrane is greater than or equal to 15 cm and is staggered from the construction joint by 1.5 to 2 meters.

[0087] Specifically, before laying the composite waterproof membrane, install circumferential drainage blind pipes. The drainage blind pipes are perforated, anti-crystallization corrugated pipes. The material, perforation rate, spacing and drainage slope of the blind pipes must meet the design and relevant specifications. The blind pipes are firmly fixed to the initial support surface with pipe clamps, laid straight, and the pipe sections are firmly connected with special joints.

[0088] When installing geotextile, use nails for fixing. The spacing between fixing points is determined according to the flatness of the base surface. When there are large local bumps, increase the number of fixing points in the concave areas to ensure that the geotextile is in close contact with the base surface. The overlap width of the geotextile seam should not be less than 50 mm.

[0089] The positioning of the waterproof membrane hanging points is controlled by an infrared laser positioning instrument or "marking points with chalk lines" to control the spacing of the hot melt gaskets. The spacing at the arch is 0.5 meters and the spacing at the side wall is 0.8 meters, using a starry pattern. Hot melt gaskets are densely arranged on both sides of the circumferential blind pipe and at the joints of the waterproof membrane. The waterproof membrane and the hot melt gaskets are fixed by a hot melt welding machine or an ultrasonic welding machine. The joints of the waterproof membrane are welded by a 3-seam double-sided climbing welding machine. The effective welding width of each weld is 15 mm. The overlap width of the waterproof membrane is not less than 15 cm. The overlap joints of the waterproof membrane are staggered from the construction joints by 1.5 to 2 meters.

[0090] According to one embodiment of the present invention, the steps for installing the lining reinforcement include:

[0091] The reinforcement bars are installed in the following order: interlayer positioning bars, outer main bars, outer longitudinal bars, inner main bars, inner longitudinal bars, structural bars, and reinforcement protective layer spacers 116.

[0092] Fix the pad 116 to the lining steel reinforcement.

[0093] Specifically, the installation sequence of the lining reinforcement is as follows: interlayer positioning reinforcement, outer layer main reinforcement, outer layer longitudinal reinforcement (pre-installed inner layer longitudinal reinforcement), inner layer main reinforcement, inner layer longitudinal reinforcement, structural reinforcement, and reinforcement protective layer spacer 116.

[0094] The reinforcing bars of the arch wall lining and the reserved reinforcing bars of the side wall shall be mechanically connected or tied. The mechanical connection shall be a compression sleeve connection. The tensile strength shall meet the requirements of the specification. The lap length of the tied connection shall be greater than or equal to 35d (d is the diameter of the main bar) and not less than 50 cm. The specifications and spacing of the reinforcing bars shall meet the design requirements and the maximum allowable deviation shall not be greater than 1 cm.

[0095] Spacers 116 should be installed between the reinforcing bars and the waterproof / drainage board, and between the reinforcing bars and the formwork. Circular concrete spacers 116 should be used to increase stability. The spacers 116 should be tightly tied to the reinforcing bars in a quincunx pattern. The material, specifications, and quantity of the spacers 116 should meet the design requirements. If there are no design requirements, the number of spacers 116 should not be less than 4 per square meter. The compressive strength and durability of the concrete spacers 116 should not be lower than the standard for arch wall concrete.

[0096] According to one embodiment of the present invention, the steps for installing and positioning the pre-embedded channel include:

[0097] Before positioning the channel, ensure the integrity of the foam filler inside the channel and make sure the distance between the end of the channel and the construction joint is greater than or equal to 100 cm.

[0098] The channel is positioned in one go, and the channel anchor rod is welded to the corresponding grounding steel bar. The lap length of the single-sided welding is greater than or equal to 100 mm, the lap length of the double-sided welding is greater than or equal to 55 mm, and the weld thickness is greater than or equal to 4 mm.

[0099] Secondary positioning of the channel: the position of the channel is adjusted by using the positioning holes reserved in the trolley panel 100 to make the channel fit tightly against the template;

[0100] The template is retracted and the fixing points of the channel are refilled with foam filler.

[0101] Specifically, the pre-embedded channel is fixed using the secondary bolt positioning hole method. The construction process is as follows: construction preparation (verify the channel model, design mileage location, and construction joint layout), 100mm opening of the lining trolley panel, channel assembly and positioning, channel grounding, verification of channel position, pouring of lining concrete, removal of formwork, and checking of channel position error.

[0102] 1. Preparations before channel positioning:

[0103] Check the integrity of the foam filler in the channel. If there are any defects, they should be filled.

[0104] According to the channel construction drawings, the channels are brought to the site in groups according to the parallel spacing designed for the channels, to avoid on-site welding.

[0105] Based on the type, model, spacing, mileage, construction joint location, tunnel alignment, and formwork trolley length, secondary bolt positioning holes are uniformly drilled at corresponding locations on the lining trolley panel 100. These holes are rectangular, 50mm x 25mm in size. For straight channels, the long side runs along the track direction; for curved channels, the long side is perpendicular to the track direction. Channels longer than or equal to 2.5 meters have three holes at both ends and in the middle; channels 1.5 meters long have two holes at both ends. If the hole positions conflict with the trolley feed inlet or connecting components, the hole positions should be adjusted appropriately along the channel. The channel positioning holes should, as far as possible, avoid the reinforcing supports of the trolley formwork 106, concrete feed inlet, hydraulic cylinders, and other components.

[0106] Strictly control the distance between the end of the channel and the end of the trolley template 106 according to the drawing requirements. The distance between the end of the channel and the construction joint shall not be less than the design value and not less than 100 centimeters.

[0107] 2. Channel positioning in one step: The channel is positioned on the lining steel reinforcement.

[0108] After binding the outer lining steel bars, measure the channel layout position according to the design position, and pre-fix the group of channels on the inner lining steel bars.

[0109] At the anchor bolts at the rear of the channel, perpendicular to the channel direction, tie 5 to 10 short reinforcing bars at intervals according to the channel length. The anchor bolts and short reinforcing bars are then tied and fixed to the lining steel bars.

[0110] According to the grounding requirements, the channel anchor rods shall be reliably welded to the corresponding grounding steel bars. The lap length of the single-sided welding shall not be less than 100 mm, the double-sided welding shall not be less than 55 mm, and the weld thickness shall not be less than 4 mm.

[0111] Remove the foam filler material at the fixing points (opening locations) between the channel and the formwork. Be careful not to remove too much filler material to prevent it from entering the channel during concrete pouring.

[0112] 3. Secondary positioning of the channel: The channel is positioned on the 100 positioning hole of the lining trolley panel.

[0113] After the trolley is moved to the predetermined position, the hydraulic cylinder lifts the arch and side wall formwork into place. Once they are close to the pre-fixed groove on the lining steel reinforcement, the position of the groove is adjusted through the positioning hole 100 reserved on the lining trolley panel.

[0114] Loosen the lower nut and use the upper nut to press the plug out of the hole. Move the plug downward and then rotate it horizontally by 90 degrees. Pass the T-bolt through the reserved positioning hole on the steel template and insert it into the channel. Tighten the nut to make the channel fit tightly against the template for precise secondary positioning on the template.

[0115] Reliable sealing measures should be implemented for unused positioning holes. Align the plug with the template hole and tighten the nut to prevent grout leakage and appearance defects after demolding.

[0116] 4. Pouring and demolding

[0117] After the trolley template 106 is sealed, the lining concrete is poured.

[0118] After loosening the T-bolt and nut, rotate the T-bolt 90 degrees to remove the bolt and retrieve the template. The T-bolt and nut must be properly stored and reused during use.

[0119] Refill the fixed points of the channel with foam filler and take protective measures.

[0120] According to one embodiment of the present invention, the assembly trolley step includes:

[0121] Soft lap joints are installed on the contact surface between the trolley and the poured concrete along the circumference of the trolley.

[0122] A steel plate is installed at the front end of the trolley to form a triangular structure with the trolley panel 100 and the trolley steel end template.

[0123] A combination of steel mold ends and polymer mold ends is used to prevent grout leakage and mold displacement at the circumferential construction joints.

[0124] The moving mold 112 is hinged to the integral side mold 114.

[0125] Specifically, in the longitudinal and circumferential soft overlap installation steps, in order to prevent the lining trolley from cracking the poured concrete, soft overlaps are used at the contact surfaces between the lining trolley and the poured concrete at the longitudinal and circumferential construction joints. The overlap width is 10 cm, and the soft overlap parts use compressible rubber strips. Pressure sensor warning devices are installed near the working platform at the circumferential soft overlap, generally no less than 5, and no less than 4 pressure sensor warning devices are installed at the soft overlap parts on both side walls. The flexible rubber strips are fixed in sections in the soft overlap slots of the trolley panel 100 (the contact points with the panel 100 are bonded to the soft overlap slots with strong adhesive and anchored to the panel 100 with anchor nails). The thickness of the rubber strips is generally 25 mm.

[0126] The longitudinal soft lap joint is installed before the lining trolley is used, and the circumferential soft lap joint is installed after the first slab and the second lining are poured, and is installed at the lap end of the lining trolley.

[0127] In the V-groove installation process at construction joints, to prevent quality defects such as localized concrete cracking, spalling, grout leakage, and concrete misalignment at the circumferential construction joint, a V-groove is installed at the end of the lining trolley. The specific construction method for the V-groove is as follows:

[0128] 1. Install (weld) a thin steel plate 50 mm wide and 6 mm thick at the front end of the trolley panel 100, forming a triangular structure with the trolley panel 100 and the trolley steel end template. The dimensions can be adjusted according to the size of the V-shaped rubber strip (generally: 40 mm high, 30 mm base width, and 50 mm hypotenuse). After completion, drill holes (5 mm in diameter) on the lining trolley immediately adjacent to the bottom edge of the inverted triangle, with a circumferential spacing of 60-80 cm, for pre-embedding iron wires (to fix the rubber strip).

[0129] 2. When pouring the secondary lining concrete, use the circumferential convex triangle at the end of the lining trolley template 106 to reserve half of a "V" shaped groove, and pre-embed No. 16 iron wire in the opening at the end of the trolley. This wire will be used to fix the V-shaped rubber strip when the next lining plate is constructed.

[0130] Before positioning the next lining trolley, fill the reserved half of the V-shaped rubber strip (specifications: bottom width 60 mm, height 40 mm) into the reserved half of the V-shaped groove, tie it with the reserved iron wire, and then fix it to the embedded waterstop 102 and U-shaped steel bar clip 104 with tie wire. It is important to ensure that the V-shaped strip is installed firmly and straight.

[0131] In the installation of the combined end formwork, to prevent grout leakage and formwork displacement at the circumferential construction joint and to ensure that the embedded waterstop 102 is centered and straight, a steel end formwork + polymer combined end formwork is used, except for the rear end formwork (or front end formwork) of the first formwork. A quick-release structure is used between the upper and lower sealing devices and between the lower sealing device and the main formwork. The lower sealing device uses a steel end formwork connected to the trolley formwork 106 by a pin shaft. The height of the steel end formwork is not less than 20 cm, and the specific height should be determined according to the centered position of the waterstop. The upper sealing device uses a telescopic adjustable polymer end formwork 118 (visible), with an adjustable height of 6 cm and a maximum adjustable height of 21 cm. A compressible rubber pad 116 replaces the spliced ​​wooden formwork. The compressible rubber pad 116 is 4 cm thick. If this device cannot meet the thickness requirements of the lining concrete pouring, an alloy pad 116 can be added between the rubber pad 116 and the polymer end formwork 118 to adjust the height. The height of the adjusting block is generally 5 cm or 10 cm.

[0132] Before installing the polymer end mold 118, the embedded rubber waterstop is fixed. In order to ensure that the waterstop is centered and vertical and to prevent the embedded waterstop 102 from deviating during the concrete pouring process, the circumferential waterstop is fixed with U-shaped steel bar clips. The U-shaped steel bar clips extend directly from between the polymer end mold 118 and the steel end mold.

[0133] The visualization modules in the polymer end mold 118 should be installed in easily observable locations and at appropriate heights. They must not be installed in a concentrated manner, but rather at corresponding positions on the arch and each observation platform, with no fewer than five modules in total. This ensures that the concrete pouring and vibration at each height of the arch can be observed through the visualization end mold from each observation platform. If wooden wedges are required for reinforcement, they must not obstruct the visualization modules, and the visualization modules must be installed on the side closest to the waterproofing membrane.

[0134] In the fixing step of the small moving formwork 112, in order to ensure that the secondary lining trolley is closely attached to the concrete of the low side wall, the smoothness of the curved wall, and the straightness of the concrete of the low side wall without misalignment or leakage, a small moving formwork 112 with a width of 45 cm is set on each side of the lining trolley. The small moving formwork 112 is connected to the overall side mold by a rotatable pin shaft. The small moving formwork 112 is supported by diagonal and vertical screw rods in a "triangular" shape to ensure its support stability.

[0135] According to one embodiment of the present invention, the steps of concrete pouring and vibration include:

[0136] At least five layers of working windows are provided on both sides of the trolley. At least three feed holes 108 and at least two vibration holes are provided in the first four layers of working windows. At least three vibration windows 110 are provided in the top layer of working windows.

[0137] Vibrate in layers with a vibration interval of 20 to 30 seconds.

[0138] Specifically, the intelligent lining trolley has five layers of working windows on each side. Layers 1 to 4 each have three material inlets (108) and two to four vibration holes. The height difference between the material outlet and inlet of the top layer window is no less than 1 meter, and the height difference between each layer window is no more than 2 meters. The fifth layer has three vibration windows (110), with an arc distance of 1.5 to 2 meters from the center line of the arch. The arch section has four fan-shaped top-punching holes, eight immersion vibrators, and eight pneumatic attached vibrators. The spacing of the high-frequency attached vibrators is calculated based on the motor power and penetration radius, and must not exceed 1.5 meters, nor more than 75 centimeters from the end of the trolley, with a rotation speed of no less than 10,000 rpm. One small attached vibrator is added near the contact channel. Small attached vibrators (with a penetration depth of over 20 centimeters) are installed at circumferential intervals of 80 to 100 centimeters, no more than 30 centimeters from the edges of both ends of the trolley.

[0139] According to one embodiment of the present invention, the concrete demolding step includes:

[0140] Once the concrete pouring is completed and the concrete strength reaches 8 MPa or above, remove the polymer composite end formwork.

[0141] During demolding, the temperature difference between the interior and surface of the concrete, and between the surface and the environment, shall not exceed 20 degrees Celsius, and the temperature difference between the inner and outer surfaces shall not exceed 15 degrees Celsius.

[0142] Specifically, after the concrete pouring is completed and the concrete strength reaches 8 MPa or higher, the polymer end formwork 118 is removed. The combined steel end formwork is then peeled off from the concrete surface in groups to expose the waterstop. The exposed steel reinforcement "U" clips are then corrected. For concrete linings constructed after the initial support deformation has stabilized, the arch concrete strength can be removed only when it reaches 10 MPa. Under special conditions, the demolding concrete strength should meet the design requirements; if no design requirements are specified, it should not be less than 70% of the design strength.

[0143] During demolding, the temperature difference between the interior and surface of the concrete, and between the surface and the environment, shall not exceed 20 degrees Celsius, and the temperature difference between the inner and outer surfaces of the structure shall not exceed 15 degrees Celsius.

[0144] According to one embodiment of the present invention, after the concrete demolding step, the method further includes:

[0145] Automated spray curing trolleys are used for maintenance.

[0146] Specifically, concrete curing must not use polluted or corrosive water sources, and the curing water must meet or exceed the standards for mixing water. The minimum curing period for concrete should be no less than 14 days, and the curing humidity should be ≥90%. During the curing period, the core temperature of the concrete should not exceed 60 degrees Celsius, and the maximum should not exceed 65 degrees Celsius. The temperature difference between the core and surface of the concrete, and the temperature difference between the surface and the ambient temperature, should not exceed 20 degrees Celsius, and the temperature difference between the curing water and the concrete surface should not exceed 15 degrees Celsius. When the ambient temperature is below 5 degrees Celsius, water should not be sprayed on the concrete surface for curing. The rate of temperature rise and fall of the surrounding environment during the curing of the lining concrete should not exceed 10 degrees Celsius per hour. The inner side of the lining concrete of the open tunnel should be insulated and moisturized, while the outer side should be covered for curing.

[0147] A second aspect of the present invention provides a system for lining concrete for an arch wall, including a trolley, on which a processor is provided, and the processor executes a program to perform the above-described method for lining concrete for an arch wall.

[0148] According to the second aspect of the present invention, the arch wall lining concrete system can automate and intelligentize the above-mentioned arch wall lining concrete method by setting a processor on the trolley and executing the corresponding program. The processor automatically executes each step of the arch wall lining concrete according to the preset program, reducing the uncertainty of manual operation and improving construction accuracy and efficiency. The processor can intelligently adjust construction parameters, such as the flatness of the concrete and the overlap width of the composite waterproofing membrane, based on real-time data and sensor feedback to ensure construction quality. The system can record key data during the construction process, facilitating subsequent analysis and optimization of the construction process, and improving project quality. By connecting with a cloud platform or other remote management system, remote monitoring and management of the construction site can be achieved, enabling timely detection and resolution of problems. The system can be integrated with other construction equipment and systems, such as concrete pouring equipment and vibration equipment, to form a complete intelligent construction system. With the development of construction technology and changes in needs, the system program can be updated and upgraded to adapt to different construction environments and requirements. Through this intelligent arch wall lining concrete system, not only can construction efficiency and quality be improved, but it can also provide construction units with a large amount of real-time data and analysis results, helping them to better grasp the construction progress and quality status, and further improve the level of construction management.

[0149] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for lining an arch wall with concrete, characterized in that, include: Initial section scanning determines that the actual flatness of the shotcrete is less than or equal to the preset flatness. When laying composite waterproof membranes, the overlap width of adjacent composite waterproof membranes is greater than or equal to a preset width value and is staggered from each other by construction joints; The steps for laying the composite waterproof membrane include: Install a circumferential drainage blind pipe; The overlap width of adjacent composite waterproof membranes is greater than or equal to 50 mm; The weld width of the composite waterproof membrane is greater than or equal to 15 cm and is staggered from the construction joint by 1.5 to 2 meters; The lining reinforcement is installed with a spacer (116) between it and the composite waterproof membrane. For the installation and positioning of the pre-embedded channel, bolt positioning holes are uniformly opened at the corresponding parts of the trolley panel (100). The pre-embedded channel is positioned at the lining steel bar once, and then positioned at the bolt positioning holes twice before finally being poured and demolded. The steps for installing and positioning the pre-embedded channel include: Preparations before channel positioning include determining the integrity of the foamed filler in the channel and ensuring that the distance between the end of the channel and the construction joint is greater than or equal to 100 cm. The channel is positioned in one go, and the channel anchor rod is welded to the corresponding grounding steel bar. The lap length of the single-sided welding is greater than or equal to 100 mm, the lap length of the double-sided welding is greater than or equal to 55 mm, and the weld thickness is greater than or equal to 4 mm. Secondary positioning of the channel: the position of the channel is adjusted by the positioning holes reserved in the trolley panel (100) so that the channel is close to the template; The template is retracted and the fixing points of the channel are refilled with foam filler. An assembly trolley is provided with soft connecting parts along the circumference of the trolley and a V-groove is installed at the front end of the panel (100) of the trolley. A combined end mold and a moving mold (112) are installed on the trolley. The steps for assembling the trolley include: A soft lap joint is provided on the contact surface between the trolley and the poured concrete along the circumference of the trolley. A steel plate is installed at the front end of the trolley to form a triangular structure with the trolley panel (100) and the trolley steel end template. A combination of steel mold ends and polymer mold ends is used to prevent grout leakage and mold displacement at circumferential construction joints. The moving mold (112) is hinged to the integral side mold (114). Concrete pouring and vibration are carried out by pouring concrete window by window, hole by hole, and layer by layer. Grouting holes and venting holes are reserved in the arch, and vibrating rods and vibrators are used together for vibration. Demolding of the concrete involves removing the combined end molds to ensure the concrete meets design strength.

2. The method for lining arch walls with concrete according to claim 1, characterized in that, The steps of the initial support section scanning include: The actual smoothness of the shotcrete is determined to be less than or equal to L / 20; The initial support section was scanned using a laser scanner. The longitudinal spacing of the scanning points was 0.3 meters for the arched section, 0.1 meters for the section without the arch, and 0.2 meters for the circumferential spacing. Where L is the distance between two adjacent convex surfaces of the base plane.

3. The method for lining arch walls with concrete according to claim 1, characterized in that, The steps for installing the reinforcing steel lining include: The reinforcement bars are installed in the following order: interlayer positioning bars, outer main bars, outer longitudinal bars, inner main bars, inner longitudinal bars, structural bars, and reinforcement protective layer spacers (116). The pad (116) is fixed to the lining reinforcement.

4. The method for lining arch walls with concrete according to claim 1, characterized in that, The concrete pouring and vibration steps include: At least five layers of working windows are provided on both sides of the trolley. At least three feed holes (108) and at least two vibration holes are provided in the first four layers of working windows, and at least three vibration windows (110) are provided in the top layer of working windows. Vibrate in layers with a vibration interval of 20 to 30 seconds.

5. The method for lining arch walls with concrete according to claim 1, characterized in that, The concrete demolding steps include: Once the concrete pouring is completed and the concrete strength reaches 8 MPa or above, the polymer composite end mold is removed. During demolding, the temperature difference between the interior and surface of the concrete, and between the surface and the environment, shall not exceed 20 degrees Celsius, and the temperature difference between the inner and outer surfaces shall not exceed 15 degrees Celsius.

6. The method for lining an arch wall with concrete according to any one of claims 1 to 5, characterized in that, Following the concrete demolding step, the following is also included: Automated spray curing trolleys are used for maintenance.

7. A system for lining concrete arch walls, characterized in that, The method includes a trolley equipped with a processor, which executes a program for performing a method for lining concrete for an arch wall as described in any one of claims 1 to 6.

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