High-precision equal-ratio uniform-seam annular array prefabricated formwork and prefabricated method thereof

Abstract

The high-precision equal-ratio uniform-seam annular array prefabricated formwork comprises a plurality of sets of prefabricated plate bases and corresponding side formwork sets, positioning protruding blocks are reserved in the centers of the tops of the prefabricated plate bases, the side formwork sets surround the positioning protruding blocks, and the side formwork sets are arranged on the periphery of the positioning protruding blocks. The overall shape defined by the side formwork sets is matched with the annular array. The side formwork set comprises two sets of arc-shaped side formworks and straight side formworks, the two sets of arc-shaped side formworks and the straight side formworks are oppositely arranged, end socket steel plate assemblies are arranged at the connecting positions of every two arc-shaped side formworks and the straight side formworks, and reinforcing assemblies are further arranged on the outer side faces of the arc-shaped side formworks and the outer side faces of the straight side formworks. According to the method, road plate precast blocks are manufactured in an equal-proportion array division mode, in precast block construction, it can be guaranteed that splicing gaps in front of each precast block plate are uniform, basalt joints in the precast blocks are uniform and flat, an arranged annular road area and overall gaps are uniform, and the flatness meets the design requirement.

Description

Technical Field

[0001] The invention specifically relates to a high-precision equal-ratio uniform-seam annular array prefabricated template and a prefabrication method thereof. Background Art

[0002] In the process of prefabrication of circular basalt, the traditional production method is to lay out basalt bricks individually like laying walkway bricks. In some specific roads, such as automobile test field roads, which are test roads, in order to ensure the stability and bearing capacity of the road structure, the base material is C35 fine stone concrete. However, a large area of ​​basalt roads needs to be laid during the construction process, which may cause uneven laying gaps, resulting in the plane elevation not meeting the requirements. In addition, this type of construction has low efficiency and a long construction period.

[0003] It is difficult to improve the uniformity and flatness of the annular basalt construction gap with existing technology, resulting in uneven size of the basalt brick joints and poor surface flatness, which affects the subsequent water film thickness and thus the test accuracy.

[0004] Therefore, it is necessary to invent a high-precision uniform-seam annular array prefabricated template and a prefabrication method thereof to solve the above problems. Summary of the invention

[0005] 1. Purpose of the invention The purpose of the present invention is to provide a high-precision equiproportioned and uniformly-seam annular array prefabricated template and a prefabrication method thereof, which solves the problems of low precision in the installation of annular basalt layout, uneven joints, and uneven horizontal elevation.

[0006] (II) Technical solution In order to achieve the above-mentioned object, the present invention provides the following technical solutions: a high-precision equiproportioned and uniformly seamed annular array prefabricated template, comprising a plurality of prefabricated plate bases and corresponding side template groups, wherein a positioning protrusion is reserved at the top center of the prefabricated plate base, the side template group is enclosed around the positioning protrusion, and the overall shape enclosed by the plurality of side template groups matches the annular array; The side formwork group includes two groups of arc-shaped side forms and a straight side formwork, the two groups of arc-shaped side forms are arranged opposite to the straight side forms, and a head steel plate assembly is provided at the connection between the two groups, and the outer side surfaces of the arc-shaped side forms and the straight side forms are also provided with a reinforcement assembly; The curvature directions of the two opposing groups of arc-shaped side molds are consistent.

[0007] Preferably, connecting holes are provided on the inner sides of the connection points between the arc-shaped side mold and the straight side mold, and multiple ribs are provided on the outer sides of the arc-shaped side mold and the straight side mold. The head steel plate assembly is installed on the connecting holes, and the head steel plate assembly includes an L-shaped steel plate, and mounting holes corresponding to the connecting holes are provided on the two vertical sides of the L-shaped steel plate, and bolts are provided in the mounting holes accordingly.

[0008] Preferably, a plurality of positioning holes cooperating with the reinforcement component are provided on the base of the prefabricated plate around the positioning protrusion, and the reinforcement component includes an installation box, and the upper and lower ends of the installation box are provided with through holes corresponding to the positioning holes, and the through holes are provided with positioning columns, and the positioning columns are inserted into the through holes until they are inserted into the positioning holes. A telescopic opening is provided at one end of the installation box, and a limiting groove is provided at the telescopic opening. Through grooves and screw holes are respectively provided on both sides of the installation box, and a reinforcement adjustment component is provided in cooperation with the screw holes and the telescopic opening.

[0009] Preferably, the reinforcement adjustment component includes a reinforcement top block, which is arranged at the telescopic opening, and a limit block is provided at one end edge of the reinforcement top block and cooperates with the limit groove, a wedge block is provided at the screw hole, a bearing is provided at one end of the wedge block, a stud is provided in the bearing, the stud is installed in cooperation with the screw hole, and a rotating handle is provided at the end of the stud, the other end of the wedge block moves correspondingly in the through groove, the straight surface of the wedge block is attached to one end of the reinforcement top block, and the inclined surface is in contact with the positioning column.

[0010] A high-precision uniform-ratio seam annular array prefabrication method comprises the following steps: S1. Plate division: divide the basalt brick ring into multiple small areas for plate division. First, divide it into large plates, and then use the large plates as the matrix to decompose and produce small plates; S2. Material preparation: prepare formwork, basalt bricks, polymer cement mortar, extruded board, pressure strips, leveling bolts, grouting holes, 4cm thick polystyrene board, and M10 mortar; S3, Formwork processing and installation: The base of the precast plate is a smooth concrete surface. When pouring on the base of the precast plate, a 2 cm thick positioning convex block 3 is reserved at the center and polished smooth, and then the side formwork is processed and installed; S4. Positioning and installation of extruded boards: According to the division of the plates, the sizes of the extruded boards are counted and cut according to the statistical table. The cut extruded boards are stored according to the numbers. The adjacent prefabricated plates and the basalt bricks on the edges are not whole blocks. High-strength extruded boards are used for positioning control and reinforcement and compaction; S5. Basalt brick laying: basalt bricks are assembled from both sides to the middle horizontally and from the inner circle to the outer circle vertically; S6. Apply polymer cement mortar: evenly apply polymer cement mortar on the upper part of the inverted basalt brick; S7. Processing of steel mesh and setting of embedded parts: install the steel mesh in the plate, and install the adjusting bolts at the four corners of the prefabricated plate. Use steel plate to process the thread. Weld the welding pipes on the upper and lower parts of the steel plate to isolate the concrete from the screw rod. The grouting holes are set close to the adjusting bolts, and the grouting holes directly pass through the steel plate holes on the steel plate. Two lifting holes are set at symmetrical positions on both sides of the plate. S8, concrete pouring: pour the concrete that meets the requirements, vibrate the concrete after pouring, and then use a trowel to finish the surface; S9, curing and demoulding: After the precast slab concrete is poured, water it in time for curing, and remove the side formwork after the concrete strength reaches 75%; S10, flipping and storing: the prefabricated panels are hoisted and flipped by a crane, and each prefabricated panel is numbered in the order of the panel division design drawings, and stored in a curing shed for watering and curing; S11. Installation and leveling: Before installation, a total station is required to conduct secondary surveying and setting out in the construction area to determine the initial installation position. The prefabricated panels are then squared and the overall flatness of the road surface is further adjusted and controlled by leveling bolts at the four corners of the determined work area. S12, Sealing: After the precast panels are leveled, cement mortar is used to seal the seams of every 5 panels in the horizontal and vertical sections; S13. Flatness test: Use a 3m ruler to test the flatness of the spliced ​​basalt road in both the vertical and horizontal directions according to the 3m*5m grid control; S14, grouting: After the precast panels are laid, the gaps between the precast panels and the base concrete are reinforced by grouting in sections; S15, patching and grouting: After grouting, remove the extruded board, remove the lower mortar cushion, install standard basalt bricks using silicone sealant, and fill the expansion joints and gaps between adjacent plates with M10 mortar; S16. Closed traffic maintenance: After the patching and grouting are completed, the traffic will be closed. People can walk after 3 days, and vehicles are allowed to enter after 7 days.

[0011] Preferably, in step 1, the center line of each row of basalt bricks is used as the dividing line of the basalt brick ring, and the difference in radius of each row of annular basalt circles plus the inner and outer ring seam values ​​are used to establish a radius arithmetic sequence with a tolerance of D1. A table is used to arrange the concentric circles of each arithmetic sequence and calculate the number of basalt bricks required for each concentric circle. Then, the arrangement position of each circle of basalt bricks is drawn. The large plates are divided according to the design drawings, and the corresponding center angle is calculated according to the arc length of the prefabricated plate. The plates are divided according to the drawings, and the last prefabricated plate is fine-tuned.

[0012] Preferably, after the bottom formwork construction in step 3 is completed, a 3-meter ruler is used to detect that the maximum gap does not exceed 2 mm. The side formwork is divided into an arc side formwork and a straight side formwork. The central angle of the arc side formwork is one-third of α, and the arc length is based on the size of the divided plate. The size of the straight side formwork is based on the size of the divided plate. A 75mm wide channel steel is selected. After the formwork is processed, the curvature and various dimensions of the formwork need to be precisely checked. After the dimensions of each formwork meet the design requirements, the formwork is installed. Before the formwork is installed, the side formwork is cleaned and a layer of demoulding oil is applied after cleaning. The arc side formwork is fixed to the prefabricated plate base 1 by welding positioning bolts. The straight side formwork is a movable formwork, and the four corners are connected with bolts. The bolt holes are designed to be flat and long.

[0013] Preferably, the flatness of the basalt bricks upon on-site acceptance in step 5 is not more than 1 mm, the joints between adjacent basalt bricks are fan-shaped with a center width of 8 mm, and are filled with 8 mm wide extruded strips, the mortar thickness in step 6 is controlled at 15 mm, 360 mm × 20 mm × 360 mm steel plates are used for threading in step 7, the screw rods use ф30 high-strength screw rods, 60 mm diameter welding pipes are welded above and below the steel plates, 60 mm welding pipes are used for the grouting holes, and 20 mm welding pipes are used for the lifting holes, the steel plates are arranged horizontally with the upper steel bars, and are firmly welded in a tic-tac-toe shape, the adjusting bolts, the grouting holes, and the lifting holes are installed straight, and both ends are sealed tightly.

[0014] Preferably, in step 9, a layer of geotextile is covered on the bottom surface of the precast panel for watering and curing, and the curing is continued for 14 days after demolding. In step 10, a gantry crane is used for hoisting, and sleepers are laid underneath the precast panels when they are stored. The precast panels are stacked up to 6 layers, and pads are set on each layer, and the positions of the pads on each layer are consistent from top to bottom.

[0015] Preferably, the transverse flatness detection in step 13 is that a 3-meter ruler coincides with and is parallel to the normal direction of the arc, the feeler gauge reading is the transverse flatness value, the longitudinal flatness detection adopts the difference detection between the arc and the corresponding chord design, and in step 14, non-shrinkage grouting material is used to be poured from the reserved grouting port, and the grouting is maintained at a uniform speed from low to high until it overflows from the grouting hole.

[0016] Compared with the prior art, the above technical solution of the present invention has the following beneficial effects: 1. The present invention is made into prefabricated road panels by dividing them into equal proportions, and during the prefabrication construction, it can ensure that the joint gaps between each prefabricated panel are uniform, and the basalt joints in the prefabricated blocks are uniform and flat; 2. The present invention can reinforce the arc-shaped side mold and the straight side mold by setting the reinforcement component on the outside of the mold. By rotating the handle, the internal wedge block is progressively moved inside, and squeezed with the positioning column to press the front reinforcement top block to make it top the column side mold. The device is convenient for reinforcing the side molds of various curvatures, ensuring the stability of the casting process; 3. The present invention ensures that the flatness of the circular road after construction meets the design requirements through operations such as initial leveling and flatness detection, and the overall gaps are uniform and neatly arranged. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0018] Figure 1 It is a schematic diagram of the overall structure of the template of the present invention; Figure 2 It is a schematic diagram of the template splitting structure of the present invention; Figure 3 This is a schematic diagram of the head steel plate installation structure of the present invention; Figure 4 Schematic diagram of the overall structure of the reinforcement assembly of the present invention Figure 1 ; Figure 5 Schematic diagram of the overall structure of the reinforcement assembly of the present invention Figure 2 ; Figure 6 It is a schematic plan view of the overall structure of the prefabricated panel module of the present invention; Figure 7 It is a schematic diagram of longitudinal flatness detection of the present invention; Figure 8 It is a schematic diagram of the installation of adjacent panels of the present invention; Fig. 9 This is a schematic diagram of the segmentation of the wet circular large plate of the present invention; Fig.10 This is a schematic diagram of the split part of the large plate of the present invention; Fig.11 It is a detailed diagram of the installation part of the small plate of the present invention; Fig.12 It is the overall construction flow chart of the present invention; Fig.13 This is a construction diagram of the prefabricated basalt plate layout of the present invention; Fig.14 It is a plane schematic diagram of the reserved grouting hole of the present invention; Fig.15 A leveling diagram for on-site installation of the panels of the present invention; Fig.16 It is the construction drawing of on-site patching and grouting of the present invention; Fig.17 This is a completed diagram of the on-site installation of the present invention.

[0019] Description of reference numerals: 1. Prefabricated plate base; 11. Positioning hole; 2. Side formwork group; 21. Arc side form; 22. Straight side form; 23. Connection hole; 24. Rib; 3. Positioning protrusion; 4. Head steel plate assembly; 41. L-shaped steel plate; 42. Mounting hole; 43. Bolt; 5. Reinforcement assembly; 51. Mounting box; 52. Through hole; 53. Positioning column; 54. Telescopic opening; 55. Limiting groove; 56. Through groove; 57. Screw hole; 58. Reinforcement adjustment assembly; 581. Reinforcement top block; 582. Limiting block; 583. Wedge block; 584. Bearing; 585. Stud; 586. Rotating handle. DETAILED DESCRIPTION

[0020] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0021] The present invention provides Figure 1-6 A high-precision, uniformly proportioned, annular array prefabricated template is shown, comprising a plurality of prefabricated panel bases 1 and corresponding side template groups 2, a positioning protrusion 3 is reserved at the top center of the prefabricated panel base 1, the side template group 2 is enclosed around the positioning protrusion 3, and the overall shape enclosed by the plurality of side template groups 2 matches the annular array; Specifically, the side mold group 2 includes two groups of arc-shaped side molds 21 and straight side molds 22. The two groups of arc-shaped side molds 21 and the straight side molds 22 are arranged opposite to each other, and a head steel plate assembly 4 is provided at the connection between the two, and a reinforcement assembly 5 is also provided on the outer side of the arc-shaped side molds 21 and the straight side molds 22; Specifically, the curvature directions of the two opposing groups of arc-shaped side molds 21 are consistent.

[0022] In the present invention, the prefabricated panel base 1 is placed at a predetermined position. Since a positioning protrusion 3 is reserved at the center of the top of the prefabricated panel base 1, the side formwork group 2 is surrounded by the positioning protrusion 3. When installing the side formwork group 2, it is placed with the positioning protrusion 3 as the center to ensure that the overall shape enclosed by the multiple side formwork groups 2 matches the annular array.

[0023] Reference Figure 3A connecting hole 23 is provided on the inner side of the connection between the arc-shaped side mold 21 and the straight side mold 22, and a plurality of ribs 24 are provided on the outer side of the arc-shaped side mold 21 and the straight side mold 22. The head steel plate assembly 4 is installed on the connecting hole 23, and the head steel plate assembly 4 includes an L-shaped steel plate 41. Mounting holes 42 corresponding to the connecting holes 23 are provided on the two vertical sides of the L-shaped steel plate 41, and bolts 43 are provided in the mounting holes 42 accordingly.

[0024] In the present invention, the side formwork group 2 includes two groups of arc-shaped side forms 21 and a straight side form 22. When assembling the side formwork group 2, the two groups of arc-shaped side forms 21 and the straight side forms 22 are placed in an opposing manner. At the connection between the two, that is, the connection between the arc-shaped side forms 21 and the straight side forms 22, the head steel plate assembly 4 is installed.

[0025] Furthermore, the inner sides of the connection between the arc side mold 21 and the straight side mold 22 are provided with connection holes 23, and the two vertical surfaces of the L-shaped steel plate 41 in the head steel plate assembly 4 are provided with mounting holes 42 corresponding to the connection holes 23. The L-shaped steel plate 41 is placed at the connection, the mounting holes 42 are aligned with the connection holes 23, and then the bolts 43 are inserted into the mounting holes 42 and tightened, thereby completing the connection between the arc side mold 21 and the straight side mold 22.

[0026] Furthermore, a plurality of ribs 24 are provided on the outer sides of the arc-shaped side mold 21 and the straight side mold 22 , and these ribs 24 can enhance the structural strength of the side mold assembly 2 .

[0027] Reference Figure 4-5 A plurality of positioning holes 11 cooperating with the reinforcement component 5 are provided around the positioning protrusion 3 on the prefabricated plate base 1. The reinforcement component 5 includes a mounting box 51. Insertion holes 52 corresponding to the positioning holes 11 are provided at the upper and lower ends of the mounting box 51. Positioning columns 53 are provided in the insertion holes 52. The positioning columns 53 are inserted into the insertion holes 52 until they are inserted into the positioning holes 11. A telescopic opening 54 is provided at one end of the mounting box 51. A limiting groove 55 is provided at the telescopic opening 54. Through grooves 56 and screw holes 57 are provided on both sides of the mounting box 51. A reinforcement adjustment component 58 is provided in cooperation with the screw holes 57 and the telescopic opening 54.

[0028] In the present invention, a plurality of positioning holes 11 are provided around the positioning protrusion 3 on the prefabricated panel base 1. The upper and lower ends of the mounting box 51 of the reinforcement component 5 are provided with insertion holes 52 corresponding to the positioning holes 11. The positioning column 53 is inserted into the insertion hole 52, and then the positioning column 53 is inserted into the positioning hole 11, so as to achieve the preliminary connection between the reinforcement component 5 and the prefabricated panel base 1.

[0029] Reference Figure 5The reinforcement adjustment component 58 includes a reinforcement top block 581, which is arranged at the telescopic opening 54, and a limit block 582 cooperating with the limit groove 55 is provided at the edge of one end thereof, a wedge block 583 is provided at the screw hole 57, a bearing 584 is provided at one end of the wedge block 583, a stud 585 is provided in the bearing 584, the stud 585 is installed in cooperation with the screw hole 57, and a rotating handle 586 is provided at the end of the stud 585, the other end of the wedge block 583 moves correspondingly in the through groove 56, the straight surface of the wedge block 583 is attached to one end of the reinforcement top block 581, and the inclined surface is in contact with the positioning column 53.

[0030] In the present invention, the reinforcement adjustment assembly 58 includes a reinforcement top block 581, a limit block 582, a wedge block 583, a bearing 584, a stud 585 and a rotating handle 586. The reinforcement top block 581 is arranged at the telescopic opening 54 of the installation box 51, and the limit block 582 at one end edge of the reinforcement top block 581 cooperates with the limit groove 55 to limit the moving direction of the reinforcement top block 581.

[0031] Furthermore, the wedge block 583 is placed at the screw hole 57, so that one end of the wedge block 583 is provided with a bearing 584, a stud 585 is installed in the bearing 584, and the stud 585 is matched with the screw hole 57. The other end of the wedge block 583 corresponds to the through groove 56, so that the straight surface of the wedge block 583 is attached to one end of the reinforcement top block 581, and the inclined surface is in contact with the positioning column 53.

[0032] Furthermore, by rotating the rotating handle 586 at the end of the stud 585, the stud 585 rotates in the screw hole 57, driving the wedge block 583 to move in the through slot 56. Since the inclined surface of the wedge block 583 contacts the positioning column 53, the movement of the wedge block 583 pushes the positioning column 53, thereby moving the reinforcement top block 581 in the telescopic opening 54, thereby achieving the reinforcement adjustment of the connection between the prefabricated panel base 1 and the side formwork group 2.

[0033] A high-precision uniform-ratio seam annular array prefabrication method comprises the following steps: S1. Plate division: divide the basalt brick ring into multiple small areas for plate division. First, divide it into large plates, and then use the large plates as the matrix to decompose and produce small plates; S2. Material preparation: prepare formwork, basalt bricks, polymer cement mortar, extruded board, pressure strips, leveling bolts, grouting holes, 4cm thick polystyrene board, and M10 mortar; S3, Formwork processing and installation: The base of the precast plate is a smooth concrete surface. When pouring on the base of the precast plate, a 2 cm thick positioning convex block 3 is reserved at the center and polished smooth, and then the side formwork is processed and installed; S4. Positioning and installation of extruded boards: According to the division of the plates, the sizes of the extruded boards are counted and cut according to the statistical table. The cut extruded boards are stored according to the numbers. The adjacent prefabricated plates and the basalt bricks on the edges are not whole blocks. High-strength extruded boards are used for positioning control and reinforcement and compaction; S5. Basalt brick laying: basalt bricks are assembled from both sides to the middle horizontally and from the inner circle to the outer circle vertically; S6. Apply polymer cement mortar: evenly apply polymer cement mortar on the upper part of the inverted basalt brick; S7. Processing of steel mesh and setting of embedded parts: install the steel mesh in the plate, and install the adjusting bolts at the four corners of the prefabricated plate. Use steel plate to process the thread. Weld the welding pipes on the upper and lower parts of the steel plate to isolate the concrete from the screw rod. The grouting holes are set close to the adjusting bolts, and the grouting holes directly pass through the steel plate holes on the steel plate. Two lifting holes are set at symmetrical positions on both sides of the plate. S8, concrete pouring: pour the concrete that meets the requirements, vibrate the concrete after pouring, and then use a trowel to finish the surface; S9, curing and demoulding: After the precast slab concrete is poured, water it in time for curing, and remove the side formwork after the concrete strength reaches 75%; S10, flipping and storing: the prefabricated panels are hoisted and flipped by a crane, and each prefabricated panel is numbered in the order of the panel division design drawings, and stored in a curing shed for watering and curing; S11. Installation and leveling: Before installation, a total station is required to conduct secondary surveying and setting out in the construction area to determine the initial installation position. The prefabricated panels are then squared and the overall flatness of the road surface is further adjusted and controlled by leveling bolts at the four corners of the determined work area. S12, Sealing: After the precast panels are leveled, cement mortar is used to seal the seams of every 5 panels in the horizontal and vertical sections; S13. Flatness test: Use a 3m ruler to test the flatness of the spliced ​​basalt road in both the vertical and horizontal directions according to the 3m*5m grid control; S14, grouting: After the precast panels are laid, the gaps between the precast panels and the base concrete are reinforced by grouting in sections; S15, patching and grouting: After grouting, remove the extruded board, remove the lower mortar cushion, install standard basalt bricks using silicone sealant, and fill the expansion joints and gaps between adjacent plates with M10 mortar; S16. Closed traffic maintenance: After the patching and grouting are completed, the traffic will be closed. People can walk after 3 days, and vehicles are allowed to enter after 7 days.

[0034] In the present invention, in step 1, the wet ring is divided into multiple small areas by using a proportional array on CAD for plate division. First, it is divided into large plates (i.e., mother units) to ensure that the integrity of each circle of basalt bricks is not destroyed. Then, the large plates are used as the mother body to decompose and produce small plates (i.e., sub-units), that is, concrete precast panels, to ensure the smooth lifting and assembly of the subsequent construction precast panels. Fig. 9 Shown is a schematic diagram of the division of large wet annular plates.

[0035] The center line of each row of basalt bricks is used as the dividing line of the circle. The difference in radius of each row of circular basalt plus the seam value of the inner and outer rings is used to establish a radius arithmetic sequence with a tolerance of D1. The EXCEL table is used to arrange the concentric circles of each arithmetic sequence and calculate the number of basalt bricks required for each concentric circle. Then the arrangement position of each circle of basalt bricks is drawn on CAD. After marking and inspection, it is 0.008m to meet the design requirements. Fig.10 Shown is a schematic diagram of a large plate being split into small plates.

[0036] The division of large panels is based on the design drawings. The corresponding center angle is calculated based on the arc length of the prefabricated panels. The panels are divided according to the drawings, and the last prefabricated panel is fine-tuned. The corresponding center angle can be calculated based on the relationship between the arc length and the radius. Draw the prefabricated blocks in CAD, and pay attention to the expansion and contraction joints between the prefabricated blocks. Fig.11 The following is a detailed diagram of the small panel installation. The calculation formula is as follows: In the present invention, the bottom formwork in step 3 is a concrete with a smooth surface. When pouring on the precast slab foundation, a 2 cm thick layer of concrete is reserved in the center position to be poured flat and polished smooth. After the construction is completed, a 3-meter ruler is used to detect that the maximum gap does not exceed 2 mm (the designed road surface flatness is 2 mm). When the basalt precast slab is constructed in a season with a large temperature difference, the flatness needs to be monitored in the morning, noon and evening before prefabrication to observe whether the bottom formwork is deformed under various temperature environments during the construction season.

[0037] In the present invention, in step 3, the side mold is divided into an arc side mold and a straight side mold, the arc side mold center angle is one third of α, the arc length is based on the size of the divided plate, and the straight side mold size is based on the size of the divided plate, and a 75mm wide channel steel is selected. The size is accurate to 1mm, the arc is accurate to 0.01°, and high-precision control is achieved.

[0038] In the present invention, after the template processing in step 3 is completed, the template curvature and various dimensions need to be accurately checked, and the chord length D and the distance between the chord and the arc are accurately marked in the CAD plate division diagram. The template diagonal size can also be directly measured on site to ensure that it is consistent with the diagonal size in CAD. The above parameters are used to conduct actual on-site inspection of the curved side formwork to ensure that it meets the design size requirements before use for construction.

[0039] In the present invention, after the size of each template meets the design requirements, the template is installed, and before the template is installed, the side template is cleaned, and after cleaning, a layer of demoulding oil is applied to facilitate later demoulding.

[0040] Furthermore, the formwork is installed in the form of "side wrapping bottom" and "arc wrapping straight". The arc side formwork and the bottom formwork are welded with positioning bolts to fix the straight side formwork as a movable formwork. The four corners are connected with bolts. The bolt holes are designed to be long and flat, and the position of the formwork can be slightly adjusted to meet the dimensional accuracy of the sub-unit plate. When installing the side formwork, the steel formwork is fixed on the outside of the formwork board using steel bars and wedge-shaped wooden blocks. The long side of the formwork is reinforced at two places and the short side is reinforced at one place. When the concrete is fully vibrated, the stability of the formwork is ensured, thereby improving the quality of concrete pouring.

[0041] Furthermore, after the side formwork is installed, the horizontal, vertical, diagonal and vertical dimensions of the formwork are reviewed. If any dimensional deviation is found, the position of the formwork is adjusted to meet the design dimensional requirements. 90-degree angle steel control angles are set at the four corners of the bottom formwork according to the standard size of the plate to ensure the size while improving efficiency.

[0042] In the present invention, in step 4, the size of each extruded board is counted in advance according to the divided plates, and the statistical accuracy is accurate to 0.1mm. According to the size statistics of the extruded board, the extruded board is cut strictly according to the size in the statistical table, and the cut extruded boards are numbered and stored in time. The basalt bricks between adjacent prefabricated plates are not whole blocks, and the position is controlled by high-strength extruded board positioning.

[0043] Furthermore, extruded boards are used for precise positioning at the edges of non-whole basalt bricks. Cut extruded boards are selected and placed in the template according to the sequence of numbers, and then reinforced and compacted.

[0044] In the present invention, the flatness of the basalt bricks in step 5 is not more than 1mm, ensuring the flatness of the entire basalt prefabricated board. According to the size and position of the drawing, the basalt bricks are assembled in reverse from both sides to the middle horizontally and from the inner circle to the outer circle vertically. The joints between adjacent basalt bricks are fan-shaped, with a center width of 8mm, and are filled with 8mm wide extruded strips to ensure that the joints between basalt bricks are consistent and meet the design requirements. Fig.13 Shown is the layout diagram of precast basalt panels.

[0045] In the present invention, the polymer cement mortar in step 6 uses finished materials, which are mixed with water according to the product design ratio (1:5) and mixed evenly using a vertical bucket mortar mixer.

[0046] Furthermore, the polymer cement mortar is evenly spread on the upper part of the inverted basalt bricks by a steel trowel, and the thickness of the mortar is controlled to be 15 mm.

[0047] In the present invention, the steel mesh in step 7 is centrally processed and manufactured in a steel bar yard, and the steel bar is installed in the board within 8 hours after the polymer cement mortar construction is completed.

[0048] Furthermore, adjusting bolts are installed at the four corners of the prefabricated board, and are threaded using 360mm×20mm×360mm steel plates. The screw rods use ф30 high-strength screw rods, and 60mm diameter welded pipes are welded above and below the steel plates to isolate the concrete from the screw rods.

[0049] Furthermore, the grouting holes are made of 60mm welded pipes, which are set close to the adjusting bolts. The grouting holes are directly punched on the 20mm thick steel plate and then set through the steel plate holes. Fig.14 Shown is a schematic diagram of the reserved grouting holes.

[0050] Furthermore, the lifting holes are made of 20mm welded pipes, and two are set symmetrically on both sides of the plate to facilitate balanced force on the plate during lifting.

[0051] Furthermore, the steel plate is set horizontally with the upper steel bars and welded firmly in a criss-cross shape. The adjusting bolts, grouting holes and lifting holes are installed straight and both ends are sealed tightly to prevent concrete from being poured into the slurry.

[0052] In the present invention, the pouring of concrete in step 8 must be completed within 12 hours after the completion of the polymer cement mortar. After the commercial concrete arrives at the site, a slump test must be performed first. Concrete pouring can only be carried out after the requirements are met (the design requirement is 160±20). When vibrating the concrete, the vibrating rod cannot be directly inserted into the bottom of the concrete for vibration to prevent damage to the position of the basalt bricks after paving. The embedded parts must not be touched to prevent the position of the embedded parts from changing and causing the adjusting bolts to become unusable. After the pouring is completed, a wooden trowel is used to finish the surface, which must ensure the flatness of the bottom of the prefabricated block and maintain the roughness of the concrete surface to facilitate bonding with the lower layer of concrete.

[0053] In the present invention, after the concrete of the precast slab is poured in step 9, water is sprinkled in time for curing. Because of the high temperature in summer, direct sunlight is prevented from causing certain damage to the precast slab. A layer of geotextile is covered on the bottom surface of the precast slab for watering and curing, which can achieve sun protection and water retention. The curing is continued for 14 days after demolding.

[0054] Furthermore, the side formwork is removed after the concrete strength reaches 75%. When removing, first remove the triangular wedge-shaped blocks on the side one by one, and then remove the square wood to ensure that the steel bars driven into the concrete base do not move, so as to facilitate the next pouring of the concrete precast slab. Open the bolts on any two sides to remove the side formwork, and so on until the formwork is removed. Violent formwork removal is strictly prohibited during the process.

[0055] In the present invention, the precast panels are hoisted by a gantry crane in step 10, and a balanced shoulder beam is used at the bottom of the crane for vertical hoisting, so as to reduce the shear force on the precast panels during the hoisting process and prevent the hoisting holes from cracking. The concrete strength during hoisting is not less than 75% of the design strength grade.

[0056] Storage of panels: After the prefabricated panels are completed, each prefabricated panel is numbered in the order of the panel division design drawings, and stored in the curing shed for watering and curing. A storage site for prefabricated panels is set up near the prefabrication site, and the site is as flat as possible to prevent deformation caused by uneven force during storage. During the storage process, a special person is arranged to test the size and flatness of each panel. Panels with geometric dimension errors greater than 4mm and maximum gaps greater than 2mm on a 3-meter ruler shall not be repaired and used. During storage, sleepers are placed underneath. The prefabricated panels are stacked up to 6 layers, with pads on each layer, and the positions of the pads on each layer are consistent.

[0057] In the present invention, before installation in step 11, a total station is required to conduct secondary measurement and layout in the construction area to determine the initial installation position, ensure that the contraction joints and expansion joints reserved in the concrete foundation are consistent with the reserved gaps after the slabs are installed, avoid quality risks caused by thermal expansion and contraction, and prevent the cumulative error of the position of the prefabricated panels from affecting the overall closure of the annular basalt pavement. The prefabricated slabs are squared on site and the overall flatness of the pavement is further adjusted and controlled by the leveling bolts at the four corners in the determined working area. Fig.15 Shown is the leveling diagram for on-site installation of the panels.

[0058] In the present invention, after the prefabricated panels are leveled in step 12, cement mortar is used to caulk every five panels in the horizontal and longitudinal sections, so as to facilitate the subsequent segmented grouting construction.

[0059] In the present invention, in step 13, a dedicated person is arranged to use a 3m ruler to test the flatness of the spliced ​​basalt road in both the vertical and horizontal directions according to a 3m×5m grid. Figure 8 Shown is a schematic diagram of the installation of adjacent panels.

[0060] Horizontal flatness detection: The 3-meter ruler is aligned and parallel to the normal direction of the arc, and the feeler gauge reading is the lateral flatness value.

[0061] Longitudinal flatness detection: adopt the difference detection of arc and corresponding chord design. Figure 7 Shown is a schematic diagram of longitudinal flatness detection.

[0062] In the present invention, after the precast panels are laid in step 14, the gaps between the precast panels and the base concrete are reinforced by grouting in sections. Use non-shrinkage grouting material to pour in from the reserved grouting port, and keep grouting at a uniform speed from low to high until it overflows from the grouting hole, so as to ensure that the lower part of the precast panels is filled densely without voids.

[0063] In the present invention, after the grouting is completed in step 15, the extruded board is removed, the lower mortar cushion layer is removed, and the standard basalt bricks are installed using silicone sealant to ensure that the shrinkage, flatness and elevation between two adjacent plates meet the requirements.

[0064] Furthermore, M10 mortar is used to fill the expansion joints and the gaps between adjacent panels. Before filling the joints, the debris in the joints should be cleaned up, the sponge strips should be filled densely, and the depth of the mortar filling should be consistent with the original precast panels, flat and straight. The mortar quality indicators are based on the quality regulations for mortar-type joint filling materials for normal temperature construction in the "Technical Specifications for Highway Cement Concrete Pavement Construction" (JTG / TF30-2014). Fig.16 Shown is the on-site patching and grouting construction drawing.

[0065] In the present invention, after the patching and grouting are completed in step 16, traffic is closed, people can walk after 3 days, and vehicles are allowed to enter after 7 days.

[0066] In the present invention, the on-site paving is changed into prefabricated panels, which are assembled on-site. The panels are precisely divided into four different small panels through high-precision proportional seam equalization technology, and then prefabricated and assembled on-site, ensuring that the gap accuracy of each panel after splicing is uniform, the splicing ring is standard, and the surface is flat and the gap is uniform, which is very beneficial for the later testing and use of the road. Fig.17 The picture shows the completed installation on site.

[0067] The above description is only by way of illustration of certain exemplary embodiments of the present invention. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A high-precision uniform-seam annular array prefabricated template, characterized in that: It comprises a plurality of groups of prefabricated panel bases (1) and corresponding side formwork groups (2), wherein a positioning protrusion (3) is reserved at the top center position of the prefabricated panel base (1), the side formwork groups (2) are surrounded by the positioning protrusion (3), and the overall shape surrounded by the plurality of side formwork groups (2) matches the annular array; The side mold assembly (2) comprises two groups of arc-shaped side molds (21) and a straight side mold (22), the two groups of the arc-shaped side molds (21) and the straight side molds (22) are arranged opposite to each other, and a head steel plate assembly (4) is provided at the connection between the two groups, and a reinforcement assembly (5) is also provided on the outer side surfaces of the arc-shaped side molds (21) and the straight side molds (22); The curvature directions of the two opposing groups of arc-shaped side molds (21) are consistent.

2. A high-precision equiproportionally uniformly seamed annular array prefabricated template according to claim 1, characterized in that: A connection hole (23) is provided on the inner side of the connection between the arc-shaped side mold (21) and the straight side mold (22), and a plurality of ribs (24) are provided on the outer side of the arc-shaped side mold (21) and the straight side mold (22). The head steel plate assembly (4) is installed on the connection hole (23), and the head steel plate assembly (4) comprises an L-shaped steel plate (41). Mounting holes (42) corresponding to the connection holes (23) are provided on two vertical surfaces of the L-shaped steel plate (41), and bolts (43) are provided in the mounting holes (42) accordingly.

3. A high-precision uniform-seam annular array prefabricated template according to claim 1, characterized in that: A plurality of positioning holes (11) cooperating with the reinforcement component (5) are provided on the base (1) of the prefabricated plate and are located around the positioning protrusion (3). The reinforcement component (5) comprises a mounting box (51). The mounting box (51) is provided with insertion holes (52) corresponding to the positioning holes (11) at the upper and lower ends. A positioning column (53) is provided in the insertion hole (52). The positioning column (53) is inserted into the insertion hole (52) until it enters the positioning hole (11). A telescopic opening (54) is provided at one end of the mounting box (51). A limiting groove (55) is provided at the telescopic opening (54). Through grooves (56) and screw holes (57) are provided on both sides of the mounting box (51). A reinforcement adjustment component (58) is provided in cooperation with the screw holes (57) and the telescopic opening (54).

4. A high-precision equiproportionally uniformly seamed annular array prefabricated template according to claim 3, characterized in that: The reinforcement adjustment component (58) comprises a reinforcement top block (581), the reinforcement top block (581) is arranged at the telescopic opening (54), and a limit block (582) is provided at one end edge thereof to cooperate with the limit groove (55), a wedge block (583) is provided at the screw hole (57), a bearing (584) is provided at one end of the wedge block (583), a stud (585) is provided in the bearing (584), the stud (585) is installed in cooperation with the screw hole (57), and a rotating handle (586) is provided at the end of the stud (585), the other end of the wedge block (583) moves in correspondence with the through groove (56), the straight surface of the wedge block (583) is in contact with one end of the reinforcement top block (581), and the inclined surface is in contact with the positioning column (53).

5. A high-precision uniform-ratio annular array prefabrication method according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1. Plate division: divide the basalt brick ring into multiple small areas for plate division. First, divide it into large plates, and then use the large plates as the matrix to decompose and produce small plates; S2. Material preparation: prepare formwork, basalt bricks, polymer cement mortar, extruded board, pressure strips, leveling bolts, grouting holes, 4cm thick polystyrene board, and M10 mortar; S3, formwork processing and installation: the precast plate base (1) is a smooth concrete surface. When pouring on the precast plate base (1), a 2 cm thick positioning convex block 3 is reserved at the center and polished to be smooth, and then the side formwork is processed and installed; S4. Positioning and installation of extruded boards: According to the division of the plates, the sizes of the extruded boards are counted and cut according to the statistical table. The cut extruded boards are stored according to the numbers. The adjacent prefabricated plates and the basalt bricks on the edges are not whole blocks. High-strength extruded boards are used for positioning control and reinforcement and compaction; S5. Basalt brick laying: basalt bricks are assembled from both sides to the middle horizontally and from the inner circle to the outer circle vertically; S6. Apply polymer cement mortar: evenly apply polymer cement mortar on the upper part of the inverted basalt brick; S7. Processing of steel mesh and setting of embedded parts: install the steel mesh in the plate, and install the adjusting bolts at the four corners of the prefabricated plate. Use steel plate to process the thread. Weld the welding pipes on the upper and lower parts of the steel plate to isolate the concrete from the screw rod. The grouting holes are set close to the adjusting bolts, and the grouting holes directly pass through the steel plate holes on the steel plate. Two lifting holes are set at symmetrical positions on both sides of the plate. S8, concrete pouring: pour the concrete that meets the requirements, vibrate the concrete after pouring, and then use a trowel to finish the surface; S9, curing and demoulding: After the precast slab concrete is poured, water it in time for curing, and remove the side formwork after the concrete strength reaches 75%; S10, flipping and storing: the prefabricated panels are hoisted and flipped by a crane, and each prefabricated panel is numbered in the order of the panel division design drawings, and stored in a curing shed for watering and curing; S11. Installation and leveling: Before installation, a total station is required to conduct secondary surveying and setting out in the construction area to determine the initial installation position. The prefabricated panels are then squared and the overall flatness of the road surface is further adjusted and controlled by leveling bolts at the four corners of the determined work area. S12, Sealing: After the precast panels are leveled, cement mortar is used to seal the seams of every 5 panels in the horizontal and vertical sections; S13. Flatness test: Use a 3m ruler to test the flatness of the spliced ​​basalt road in both the vertical and horizontal directions according to the 3m*5m grid control; S14, grouting: After the precast panels are laid, the gaps between the precast panels and the base concrete are reinforced by grouting in sections; S15, patching and grouting: After grouting, remove the extruded board, remove the lower mortar cushion, install standard basalt bricks using silicone sealant, and fill the expansion joints and gaps between adjacent plates with M10 mortar; S16. Closed traffic maintenance: After the patching and grouting are completed, the traffic will be closed. People can walk after 3 days, and vehicles are allowed to enter after 7 days.

6. A high-precision uniform-ratio annular array prefabrication method according to claim 5, characterized in that: In the step 1, the center line of each row of basalt bricks is used as the dividing line of the basalt brick ring, and the difference in radius of each row of annular basalt circles plus the seam value of the inner and outer rings are used to establish a radius arithmetic sequence with a tolerance of D1. A table is used to arrange the concentric circles of each arithmetic sequence and calculate the number of basalt bricks required for each concentric circle. Then, the arrangement position of each circle of basalt bricks is drawn. The large plates are divided according to the design drawings, and the corresponding center angle is calculated according to the arc length of the prefabricated plate. The plates are divided according to the drawings, and the last prefabricated plate is fine-tuned.

7. A high-precision uniform-ratio annular array prefabrication method according to claim 6, characterized in that: After the bottom formwork construction in step 3 is completed, a 3-meter ruler is used to check that the maximum gap does not exceed 2mm. The side formwork is divided into an arc side formwork and a straight side formwork. The central angle of the arc side formwork is one-third of α, and the arc length is based on the size of the divided plate. The size of the straight side formwork is based on the size of the divided plate. A 75mm wide channel steel is selected. After the formwork is processed, the curvature and various dimensions of the formwork need to be precisely checked. After the dimensions of each formwork meet the design requirements, the formwork is installed. Before the formwork is installed, the side formwork is cleaned and a layer of demoulding oil is applied after cleaning. The arc side formwork is fixed to the prefabricated plate base 1 by welding positioning bolts. The straight side formwork is a movable formwork, and the four corners are connected with bolts. The bolt holes are designed to be flat and long.

8. A high-precision uniform-ratio annular array prefabrication method according to claim 6, characterized in that: The flatness of the basalt bricks described in step 5 is not more than 1mm upon on-site acceptance. The joints between adjacent basalt bricks are fan-shaped with a center width of 8mm, and are filled with 8mm wide extruded strips. The mortar thickness in step 6 is controlled at 15mm. In step 7, 360mm×20mm×360mm steel plates are used for threading. The screw rods use ф30 high-strength screw rods. 60mm diameter welding pipes are welded on the upper and lower parts of the steel plates. 60mm welding pipes are used for the grouting holes, and 20mm welding pipes are used for the lifting holes. The steel plates are arranged horizontally with the upper steel bars and are firmly welded in a tic-tac-toe shape. The adjusting bolts, the grouting holes, and the lifting holes are installed straight, and both ends are sealed tightly.

9. A high-precision uniform-ratio annular array prefabrication method according to claim 6, characterized in that: In the step 9, a layer of geotextile is covered on the bottom surface of the precast panel for watering and curing, and the curing is continued for 14 days after demoulding. In the step 10, a gantry crane is used for hoisting, and sleepers are placed underneath the precast panels when they are stored. The precast panels can be stacked up to 6 layers, and pads are set on each layer, and the positions of the pads on each layer are consistent.

10. A high-precision uniform-ratio annular array prefabrication method according to claim 6, characterized in that: The transverse flatness detection in step 13 is that the 3-meter ruler coincides with and is parallel to the normal direction of the arc, and the feeler gauge reading is the transverse flatness value. The longitudinal flatness detection adopts the difference detection between the arc and the corresponding chord design. In step 14, non-shrinkage grouting material is used to be poured from the reserved grouting port, and the grouting is maintained at a uniform speed from low to high until it overflows from the grouting hole.

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