Tunnel grating steel frame modular integration and its rapid and accurate installation method

Abstract

The present application relates to the technical field of tunnel steel frame installation, especially to a tunnel grid steel frame modular integration and its rapid and accurate installation method, comprising the following steps: processing large-specification steel mesh, controlling the tooth disc by increasing differential spacing, lengthening the steel mesh receiving platform, and adjusting the length of the blank to realize the production spacing differentiation and the modular integrated unit control size of the steel mesh; reasonably dividing the grid steel frame into sections, each section being no more than 9m, and completing the integrated welding of the matching size steel mesh, steel frame and connecting rib in the steel structure processing plant; through the processing of large-specification steel mesh, not only the material waste is reduced, but also the production efficiency and economic benefits are improved. Secondly, the design of the modular integrated unit enables the steel frame, steel mesh and connecting rib to be integrated in the factory, reducing the complexity and time of on-site operation, and reducing the construction risk.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of tunnel steel frame installation, in particular to a tunnel grid steel frame modular integration and its rapid and accurate installation method. BACKGROUND

[0002] With the rapid development of China's high-speed railway, highway and other transportation construction, the number of tunnel construction is becoming larger and larger, and the construction scale is becoming larger and larger. As the most basic method of tunnel, the new Austrian tunneling method is most widely used, which fully utilizes the self-bearing capacity of surrounding rock and the space constraint effect of the excavation face, and adopts anchor rod and sprayed concrete as the main support means. In the tunnel anchor and sprayed support construction, grade IV and grade V surrounding rock mainly adopts steel arch frame net anchor and sprayed support type. Steel arch frame is divided into grid steel arch and section steel arch, and grid arch is used in the case of relatively good surrounding rock (less collapse, relatively less backfill concrete); section steel arch is used in the case of relatively poor surrounding rock (encountering large collapse, large amount of backfill sprayed concrete, and large early bearing capacity of section steel arch).

[0003] The traditional arch installation construction in China mainly adopts excavation bench auxiliary manual construction, and the arch, mesh and connecting rib are all scattered, which need to be assembled on site in a fragmented manner. Since this installation method requires more construction personnel, has high labor intensity, low work efficiency and high construction risk. Therefore, arch installation machine is more and more widely used, and the section steel arch has large quality, large hardness and relatively large rigidity, so that the use of arch installation machine in section steel arch installation construction can effectively improve the work efficiency and installation accuracy. However, the grid steel frame is flexible and easy to deform, so that the installation accuracy is poor and the installation efficiency is low during the use of the steel frame installation frame, and the grid arch is easy to deform when the arch installation machine installs the grid arch, thereby restricting the application of the arch installation machine in the grid steel frame construction. In order to solve the above problems, the China Railway Fourth Bureau has carried out research on the grid steel frame modular integration and rapid and accurate installation method, so as to ensure the accurate installation of the arch, stable quality and rapid construction, and achieve the goal of high quality, economy and high efficiency. SUMMARY

[0004] In view of the above or the problem in the prior art that the grid steel frame is flexible and easy to deform, the installation accuracy is poor and the installation efficiency is low during the use of the steel frame installation frame, and the grid arch is easy to deform when the arch installation machine installs the grid arch, thereby restricting the application of the arch installation machine in the grid steel frame construction, the present application is proposed.

[0005] Therefore, the purpose of the present application is to provide a tunnel grid steel frame modular integration and its rapid and accurate installation method.

[0006] To solve the above technical problems, the present application provides the following technical solutions: including the following steps, processing large specification steel mesh, controlling the tooth disc by increasing the differentiated spacing, lengthening the steel mesh receiving platform, adjusting the length of the blank, to realize the production spacing differentiation and the modular integrated unit control size of the steel mesh; reasonably dividing the grid steel frame, each section being not more than 9m, and completing the integrated welding of the matching size steel mesh, the steel frame and the connecting rib in the steel structure processing plant.

[0007] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: the large specification steel mesh processing further includes that the lap length of two meshes meeting the requirement of not less than one mesh.

[0008] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: the modular integrated unit is completed in the steel structure processing plant, so as to reduce the lap loss of the steel mesh and the connecting rib, and optimize the on-site assembly process.

[0009] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: the horizontal lifting beam is improved on the small arm below the grabbing head of the two side arms of the arch installation machine, and the bearing rotary hook is installed on the side of the grabbing head.

[0010] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: the bolt buckle type tooling and the laser pen are installed on the formed grid steel frame, and the 7-point laser positioning is formed.

[0011] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: including the following steps: completing the modular integrated grid steel frame in the steel structure processing plant; installing the seven-point laser positioning tooling; using the total station instrument to lay out the laser positioning point; sequentially installing the grid steel frame modular unit from top to bottom; welding the connecting rib of the previous cycle; setting the locking foot and welding; recovering the 7-point laser positioning.

[0012] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: the vertical frame precision review is strengthened; the installation precision of the last steel frame of each cycle is measured; the arch foot virtual slag is cleaned, and the concrete pad is used to pad.

[0013] As a preferred scheme of the tunnel grid steel frame modular integration and its rapid and accurate installation method of the present application, wherein: the drainage ditch is dug, and the accumulated water is pumped out in time; the tunnel construction principle is adhered to.

[0014] As a preferred embodiment of the modular integration of tunnel grid steel frame and its rapid and precise installation method of the present invention, the processing accuracy of the steel frame at the steel structure plant is checked weekly and corrected in a timely manner.

[0015] As a preferred embodiment of the modular integration of tunnel grid steel frame and its rapid and precise installation method of the present invention, the modular steel frame units are transported by truck-mounted cranes, and violent loading and unloading that may cause deformation is prohibited, and the steel frame is protected to prevent corrosion.

[0016] The beneficial effects of this invention's modular integration of tunnel grating steel frames and its rapid and precise installation method are as follows: Firstly, the processing of large-size steel mesh not only reduces material waste but also improves production efficiency and economic benefits. Secondly, the modular integration unit design allows for the integrated assembly of the steel frame, steel mesh, and connecting bars in the factory, reducing the complexity and time required for on-site operations and lowering construction risks. Furthermore, the application of modified support beams and bearing-rotating hooks optimizes the arch frame installation method, preventing deformation of the grating steel frame and improving installation accuracy. The use of a 7-point laser positioning fixture for the bolt-locking arch frame further improves the accuracy of the erection, ensuring construction quality. Overall, this technology achieves rapid and precise installation of tunnel grating steel frames, accelerating construction progress, improving construction quality, and reducing construction costs, providing an efficient and reliable solution for modern tunnel engineering construction. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 Schematic diagram of seven-point laser positioning

[0019] Figure 2 Flowchart of rapid and precise installation process for modular integrated grating steel frame

[0020] Figure 3 Schematic diagram for rapid and precise installation of modular integrated grating steel frame

[0021] Figure 4 Diagram illustrating laser positioning.

[0022] Figure 5 This is a schematic diagram of the locking pin welding. Detailed Implementation

[0023] In order to make the above objectives, features and advantages of the present application more apparent, a detailed description of the specific embodiments of the present application will be given below with reference to the accompanying drawings.

[0024] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. However, it will be apparent to one skilled in the art that the present application can be practiced without the specific details given below. In other instances, well-known methods have not been described in detail in order to avoid unnecessarily obscuring the present application.

[0025] Secondly, the "one embodiment" or "embodiment" referred to herein means that the specific features, structures or characteristics can be included in at least one implementation of the present application. "In one embodiment" appearing in different places in the specification does not mean the same embodiment, nor is it an embodiment that is independent or alternative to other embodiments.

[0026] Embodiment 1, refer to Figures 1 to 5 For the first embodiment of the present application, the embodiment provides a tunnel grid steel frame modular integration and its fast and accurate installation method. First, a differential spacing control tooth disc is set in a steel structure processing plant to adjust the spacing of the steel mesh to meet the needs of different tunnel sections. Then, the steel mesh receiving platform is lengthened to optimize the processing flow of the steel mesh. By adjusting the length of the material, the size of the steel mesh is ensured to match the modular integrated unit. During the processing, special attention is paid to the lap length of the two meshes to ensure that it is not less than one mesh to reduce material waste and improve work efficiency.

[0027] Embodiment 2, refer to Figures 1-5 For the second embodiment of the present application, in this embodiment, the grid steel frame is reasonably segmented, and the length of each section is controlled between 4-5 meters to avoid deformation during transportation caused by the excessive weight of a single section. In the steel structure processing plant, a plurality of steel frame modular integrations are carried out on each section to complete the integrated welding of the steel mesh, steel frame and connecting rib of matching size. During the welding process, appropriate exposed and overlapping parts are reserved to facilitate fast installation on site. The completed modular unit is transported to the tunnel construction site by a truck-mounted crane and stacked using a support to prevent deformation caused by chaotic stacking of the modules.

[0028] Embodiment 3, refer to Figures 1-5For the third embodiment of the present application, different from the last embodiment, the embodiment provides a tunnel grid steel frame modular integration and its fast and accurate installation method. In the embodiment, first, the bolt buckle type tooling and the laser pen are installed on the formed grid steel frame in the upper cycle, and are positioned at 10cm on the normal vault, the haunch connecting plate, 10cm on the side wall connecting plate and 70cm on the arch foot. The total station is used to place the laser layout point according to the disclosed steel frame section, and the laser pen is fixed. The 7-point laser positioning is used as the reference datum of the vertical frame, and the vertical frame is adjusted in real time to control the steel frame, so as to ensure the accurate vertical frame. Then, the grid steel frame modular units are installed in sequence from top to bottom, starting from the vault module and symmetrically installed downwards, and the bolt connection is sequentially installed. After the arch foot module is installed, the steel frame is accurately positioned and all the bolts are fastened, and the assembly of multiple grid steel frames is completed.

[0029] Importantly, it should be noted that the construction and arrangement of the application shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications can be made to the embodiments without materially departing from the novel teachings and advantages of the subject matter described in this application (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, elements shown as integrally formed can be constructed of multiple parts or elements, the position of elements can be reversed or otherwise varied, and the nature or number of elements or positions can be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps can be changed or re-sequenced without departing from the generality of the application. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions can be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present application. Accordingly, the present application is not limited to the particular embodiments described but extends to the scope of the appended claims.

[0030] Furthermore, in an effort to provide a concise description of exemplary embodiments, all features of an actual implementation can not be described (i.e., those unrelated to the presently contemplated best mode of carrying out the application, or those unrelated to enabling the application).

[0031] It should be understood that numerous specific implementation decisions can be made during the development of any practical implementation, such as in any engineering or design project. Such development efforts may be complex and time-consuming, but for those skilled in the art who benefit from this disclosure, the development effort will be a routine work of design, manufacturing, and production without requiring much experimentation.

[0032] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A modular integration of tunnel grid steel frames and its rapid and precise installation method, characterized in that: It comprises the following steps: Processing large-scale steel mesh, controlling the toothed disc by increasing the differentiated spacing, lengthening the steel mesh receiving platform, and adjusting the length of the cut piece to realize the production of steel mesh with differentiated spacing and modular integrated unit control size; Reasonably dividing the grid steel frame into sections, each section not exceeding 9m, and completing the integrated welding of the matching size steel mesh, steel frame and connecting rib in the steel structure processing plant; The large-scale steel mesh processing further comprises that the lap length of the lap joint of two pieces of mesh should not be less than one grid; It also includes modifying the lifting beam, improving the installation of the transverse lifting beam on the small arm below the grabbing head of the two side arms of the arch installation machine, and installing bearing rotary hooks on the side of the grabbing head; Installing the bolt buckle type tooling and laser pen on the formed grid steel frame to form 7-point laser positioning; The installation process includes: completing the modular integrated grid steel frame in the steel structure processing plant; Installing the seven-point laser positioning tooling; Using the total station to layout the laser positioning point; Installing the grid steel frame modular unit from top to bottom in turn; Welding the connecting rib of the previous cycle; Setting the locking foot and welding; Retrieving the 7-point laser positioning; It also includes quality control measures, which include: strengthening the precision review of the vertical frame; Re-measuring the installation accuracy of the last steel frame of each cycle; Cleaning the dummy slag at the arch foot and using concrete pads to pad it solidly; Using the truck-mounted crane to transport the modular steel frame unit, prohibiting violent loading and unloading to cause deformation, and strengthening the protection of the steel frame to prevent rust.

2. A modular integration of tunnel lattice steel framing and its fast and accurate installation method as claimed in claim 1, wherein: The modular integrated unit is completed in the steel structure processing plant to reduce the lap loss of steel mesh and connecting rib and optimize the on-site assembly process.

3. A modular integration of tunnel lattice steel framing and its fast and accurate installation method as claimed in claim 2, wherein, The quality control measures further include: Digging drainage ditches and promptly pumping out accumulated water; Adhering to the principles of tunnel construction.

4. A modular integration of tunnel lattice steel framing and its fast and accurate installation method as claimed in claim 3, wherein, The quality control measures further include: rechecking the steel frame processing accuracy in the steel structure plant every week and timely correcting the deviation.

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