Rapid prefabrication construction method for large-size multi-segment concrete immersed tubes in small dry dock

Abstract

A method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock, wherein the first immersed tube prefabrication area and the second immersed tube prefabrication area at the construction site in the dry dock are both arranged longitudinally and are both located in front of the third immersed tube prefabrication area, and the third immersed tube prefabrication area is arranged transversely so as to be arranged in a herringbone shape with the first immersed tube prefabrication area and the second immersed tube prefabrication area, and the specific construction steps include a first prefabrication route and a second prefabrication route that are carried out simultaneously. In the embodiment of the present invention, the two prefabrication routes are carried out simultaneously, and the prefabrication of multiple immersed tubes is carried out at the same time, and the first set of prefabrication molds in the first prefabrication route are first moved in a direction away from the third immersed tube prefabrication area, thereby avoiding the first set of prefabrication molds and the second set of prefabrication molds from interfering with each other in the narrow space between the first immersed tube prefabrication area and the third immersed tube prefabrication area, ensuring that the two prefabrication routes are carried out synchronously and smoothly in a limited space, and shortening the construction period of all immersed tube prefabrication.

Description

Technical Field

[0001] The invention belongs to the technical field of immersed tube tunnel construction, and in particular relates to a rapid prefabrication construction method for a large-size multi-segment concrete immersed tube in a small dry dock. Background Art

[0002] During the construction of immersed tube tunnels, a dry dock must first be built on the embankment so that the immersed tubes can be prefabricated in the dry dock. The construction of the dry dock is one of the key links in the construction of immersed tube tunnels, because the prefabrication quality of the immersed tubes directly affects the overall structural safety and durability of the tunnel. However, the construction of immersed tube tunnels faces many challenges and limitations, which puts higher requirements on the construction progress and quality.

[0003] At present, there are several main problems in the construction process of immersed tube tunnels:

[0004] 1. Installation window restrictions: The installation of immersed tube tunnels needs to be completed within a specific time window to ensure that environmental conditions (such as tides, water flow, etc.) are most favorable during the installation process. This installation window restriction leads to a tight construction schedule, and any delay may have a significant impact on the progress of the entire project.

[0005] 2. Limited construction site: The construction of a dry dock requires a certain amount of land. However, there are usually some existing buildings and facilities around the dry dock, which limits the area occupied by the dry dock. This makes the dry dock a small dry dock with a relatively small construction area, which cannot meet the space requirements for large-scale immersed tube prefabrication.

[0006] 3. Large-section structure of immersed tube: The large-section structure of immersed tube means that the volume, weight and span of a single immersed tube are very large. The prefabrication of immersed tubes needs to occupy most of the construction area in the dry dock, leaving only a small space for material circulation and prefabrication mold transportation, making the corresponding operation difficult.

[0007] 4. Assembly of mold trolley and steel bar binding frame: In the dry dock, not only the immersed tube needs to be prefabricated, but also the mold trolley and steel bar binding frame need to be assembled. These operations require a lot of construction equipment and space, making the construction arrangement in the dry dock more complicated.

[0008] In summary, it is very difficult to plan the overall construction under the above constraints, so as to reasonably arrange the connection between the various construction processes within the limited construction site and ensure the prefabrication of the immersed tube is completed on schedule. Effectively solving these problems is of great significance to improving construction efficiency, ensuring project quality and completing construction tasks on time. Summary of the invention

[0009] In view of the shortcomings existing in the related technology, the present invention provides a rapid prefabrication construction method for large-size multi-segment concrete immersed tubes in a small dry dock, so as to solve the current problems of short prefabrication period of large-section immersed tubes and small prefabrication and circulation areas leading to difficulty in overall planning.

[0010] The present invention provides a method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock. A first immersed tube prefabrication area, a second immersed tube prefabrication area and a third immersed tube prefabrication area are arranged at a construction site in the dry dock. The first immersed tube prefabrication area and the second immersed tube prefabrication area are both arranged longitudinally and are both located in front of the third immersed tube prefabrication area. The third immersed tube prefabrication area is arranged transversely so as to be arranged in a herringbone shape with the first immersed tube prefabrication area and the second immersed tube prefabrication area. The dry dock has a dock door, and the front end of the first immersed tube prefabrication area faces the dock door. The specific construction steps are as follows:

[0011] First prefabrication route:

[0012] Using the first set of prefabrication molds, starting from the rear end of the first immersed tube prefabrication area, multiple tube sections of the first immersed tube are prefabricated from the rear to the front, and the first set of prefabrication molds are transported from the front end of the first immersed tube prefabrication area to the front end of the second immersed tube prefabrication area, and starting from the front end of the second immersed tube prefabrication area, multiple tube sections of the second immersed tube are prefabricated from the front to the back;

[0013] Second prefabrication route:

[0014] In parallel with the first prefabrication route, a second set of prefabrication molds is used to prefabricate the respective tube sections of the third immersed tube starting from one end of the third immersed tube prefabrication area away from the first immersed tube prefabrication area toward the other end thereof;

[0015] Wherein, the prefabricated mold includes a template trolley, and the first set of prefabricated molds further includes a steel bar binding frame.

[0016] In some embodiments, the plurality of pipe sections of the first immersed tube are arranged one by one in sequence from rear to front, so that the first pipe section of the first immersed tube is located at the rear end;

[0017] In the first prefabrication route step, the second pipe section of the first immersed tube is prefabricated first, then the first pipe section of the first immersed tube is prefabricated, and then the third pipe section of the first immersed tube is prefabricated, and the subsequent pipe sections of the first immersed tube are prefabricated one by one in sequence from the back to the front;

[0018] When prefabricating the second pipe section of the first immersed tube, the prefabrication molds are assembled one by one at the rear end of the first immersed tube prefabrication area, and the assembled prefabrication molds are transported forward to be used for prefabrication of the second pipe section of the first immersed tube.

[0019] In some embodiments, the steel bar binding frame includes a side wall steel bar binding frame and a top plate steel bar binding frame, the template trolley includes an outer template trolley and an inner template trolley, and the specific steps of prefabrication of the pipe segment are as follows:

[0020] Lay waterproof bottom steel plates in the dry dock bottom tire area, install the bottom plate rigid frame and tie the bottom plate reinforcement on the waterproof bottom steel plates;

[0021] Install the side wall rigid frame and the partition wall rigid frame on the bottom plate rigid frame, and use the side wall steel bar binding frame to bind the side wall steel bars and the partition wall steel bars;

[0022] Install the top plate rigid frame on the side wall rigid frame and the partition wall rigid frame, and use the top plate steel bar binding frame to bind the top plate steel bars;

[0023] The trusses of the outer formwork trolley are connected to the top plate reinforcement through steel strands to complete the conversion of the support system;

[0024] Concrete pouring between the formwork trolleys;

[0025] Among them, when laying the waterproof bottom steel plate, assemble the side wall steel bar tying frame; when tying the side wall steel bars and partition wall steel bars, assemble the top plate steel bar tying frame; when tying the top plate steel bars, assemble the outer mold trolley; when converting the support system, assemble the inner mold trolley.

[0026] In some of the embodiments, when subsequent pipe sections are prefabricated one by one starting from the third pipe section of the first immersed tube in the first prefabrication route step, and when each pipe section of the third immersed tube is prefabricated one by one from one end to the other end in the second prefabrication route step, when the prefabrication of the previous pipe section proceeds to the tying of the bottom plate reinforcement, the prefabrication of the next pipe section proceeds to the laying of the waterproof bottom steel plate; when the prefabrication of the previous pipe section proceeds to the tying of the side wall reinforcement, the prefabrication of the next pipe section proceeds to the tying of the bottom plate reinforcement; when the prefabrication of the previous pipe section proceeds to the tying of the top plate reinforcement, the prefabrication of the next pipe section proceeds to the tying of the side wall reinforcement; when the prefabrication of the previous pipe section proceeds to the tying of the top plate reinforcement, the prefabrication of the next pipe section proceeds to the tying of the side wall reinforcement; when the prefabrication of the previous pipe section proceeds to the conversion of the support system, the prefabrication of the next pipe section proceeds to the tying of the top plate reinforcement.

[0027] In some of the embodiments, in the second prefabrication route step, the prefabrication mold used only includes an outer mold trolley and an inner mold trolley; the side wall reinforcement and partition wall reinforcement are tied using the support frames on both sides of the outer mold trolley, and after the side wall reinforcement and partition wall reinforcement are tied, the top plate reinforcement is tied using the inner mold trolley.

[0028] In some of the embodiments, when prefabricating the pipe sections at both ends of the immersed tube, the end molds and the embedded steel-edge rubber waterstop are installed between the template trolleys after the support system is converted, and then the end steel shell is further installed.

[0029] In some embodiments, the template trolley includes an outer template trolley, and the outer template trolley is transported from the front end of the first immersed tube prefabrication area to the front end of the second immersed tube prefabrication area, and the specific steps are as follows:

[0030] The outer mold trolley is evenly divided into a first outer trolley part and a second outer trolley part front and back;

[0031] The first outer trolley is moved forward to remove the prefabricated pipe section, and then translated to the front side of the second immersed tube prefabrication area, the first outer trolley is rotated 90 degrees to the longitudinal direction, and is moved to the side of the second immersed tube prefabrication area away from the first immersed tube prefabrication area;

[0032] The second outer trolley is moved forward to remove the prefabricated pipe section, and then translated to the front side of the second immersed tube prefabrication area, and the second outer trolley is rotated so that one end of the second immersed tube prefabrication area is above the second immersed tube prefabrication area and the other end is between the first immersed tube prefabrication area and the second immersed tube prefabrication area, and then translated to the rear side of the first outer trolley and rotated to the horizontal direction;

[0033] The first outer trolley portion is rotated to the horizontal direction and assembled with the second outer trolley portion at the rear side to form an outer mold trolley, and the outer mold trolley is moved to the front end of the second immersed tube prefabrication area.

[0034] In some embodiments, the template trolley includes an inner mold trolley, and the inner mold trolley is transported from the front end of the first immersed tube prefabrication area to the front end of the second immersed tube prefabrication area, and the specific steps are as follows:

[0035] The inner mold trolley is evenly divided into a first inner trolley part and a second inner trolley part front and back;

[0036] The first inner carriage part is moved forward to remove the prefabricated pipe segment and horizontally moved to the docking area;

[0037] The second inner trolley part is moved forward to remove the prefabricated pipe segment, and is translated horizontally and vertically to the front end of the second immersed tube prefabrication area;

[0038] The first inner trolley portion is moved backward out of the dock area, and is translated horizontally and vertically to the front end of the second immersed tube prefabrication area, and is further assembled with the second inner trolley portion at the rear side to form an inner mold trolley.

[0039] In some embodiments, the steel reinforcement skeleton of the pipe segment is divided into a bottom plate portion, two side wall portions, two middle wall portions and a top plate portion, and the concrete pouring steps of the pipe segment are as follows:

[0040] The bottom plate is poured in multiple layers. The two ends and the middle are poured first, and then the remaining part under the roadway is poured. The part of each layer of concrete poured under the roadway is inclined downward.

[0041] Multi-layer pouring of side walls and middle walls;

[0042] The top plate is poured in multiple layers from both ends to the middle, and each layer of concrete is poured with a downward slope.

[0043] In some of these embodiments, the concrete on both sides of the underside of the carriageway intersects with each other.

[0044] Based on the above technical scheme, in the embodiment of the present invention, two prefabrication routes are carried out simultaneously, and prefabrication of multiple immersed tubes is carried out at the same time, and the first set of prefabrication molds in the first prefabrication route is first moved in the direction away from the third immersed tube prefabrication area, so as to avoid the first set of prefabrication molds and the second set of prefabrication molds from interfering with each other in the narrow space between the first immersed tube prefabrication area and the third immersed tube prefabrication area, thereby ensuring that the two prefabrication routes are carried out synchronously and smoothly within a limited space, shortening the construction period of all immersed tube prefabrication, and solving the problem that the current prefabrication period of large-section immersed tubes is short and the prefabrication and circulation areas are small, resulting in difficulties in overall planning. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0046] Figure 1 It is a layout diagram of the immersed tube prefabrication area in the dry dock and the corresponding immersed tube segments to be prefabricated in the small dry dock large-size multi-segment concrete immersed tube rapid prefabrication construction method of the present invention;

[0047] Figure 2 It is a process flow chart of the rapid prefabrication construction method of a large-size multi-segment concrete immersed pipe in a small dry dock of the present invention;

[0048] Figure 3 Schematic diagram of the construction of prefabricating the first immersed tube segment on the first prefabrication route in the method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to the present invention Figure 1 ;

[0049] Figure 4 Schematic diagram of the construction of prefabricating the first immersed tube segment on the first prefabrication route in the method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to the present invention Figure 2 ;

[0050] Figure 5 Schematic diagram of the construction of prefabricating the first immersed tube segment on the first prefabrication route in the method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to the present invention Figure 3 ;

[0051] Figure 6 Schematic diagram of the construction of prefabricating the first immersed tube segment on the first prefabrication route in the method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to the present invention Figure 4 ;

[0052] Figure 7 The schematic diagram of the construction of the reverse transportation of the outer formwork stand in the fast prefabrication construction method of large-size multi-segment concrete immersed pipe in a small dry dock of the present invention is shown in FIG. Figure 1 ;

[0053] Figure 8 The schematic diagram of the construction of the reverse transportation of the outer formwork stand in the fast prefabrication construction method of large-size multi-segment concrete immersed pipe in a small dry dock of the present invention is shown in FIG. Figure 2 ;

[0054] Fig. 9 The schematic diagram of the construction of the reverse transportation of the inner formwork stand in the fast prefabrication construction method of large-size multi-segment concrete immersed pipe in a small dry dock of the present invention is shown in FIG. Figure 1 ;

[0055] Fig.10 The schematic diagram of the construction of the reverse transportation of the inner formwork stand in the fast prefabrication construction method of large-size multi-segment concrete immersed pipe in a small dry dock of the present invention is shown in FIG. Figure 2 ;

[0056] Fig.11 The schematic diagram of the construction of the middle gallery formwork trolley in the fast prefabrication construction method of large-size multi-segment concrete immersed pipe in a small dry dock of the present invention is shown in FIG. Figure 1 ;

[0057] Fig.12 The schematic diagram of the construction of the middle gallery formwork trolley in the fast prefabrication construction method of large-size multi-segment concrete immersed pipe in a small dry dock of the present invention is shown in FIG. Figure 2 ;

[0058] Fig.13 The schematic diagram of the construction of pipe segment concrete pouring in the method for rapid prefabrication of large-size multi-segment concrete immersed pipes in a small dry dock of the present invention is shown in FIG. Figure 1 ;

[0059] Fig.14 The schematic diagram of the construction of pipe segment concrete pouring in the method for rapid prefabrication of large-size multi-segment concrete immersed pipes in a small dry dock of the present invention is shown in FIG. Figure 2 ;

[0060] Fig.15 The schematic diagram of the construction of pipe segment concrete pouring in the method for rapid prefabrication of large-size multi-segment concrete immersed pipes in a small dry dock of the present invention is shown in FIG. Figure 3 ;

[0061] Fig.16 The schematic diagram of the construction of pipe segment concrete pouring in the method for rapid prefabrication of large-size multi-segment concrete immersed pipes in a small dry dock of the present invention is shown in FIG. Figure 4 ;

[0062] Fig.17 The schematic diagram of the construction of pipe segment concrete pouring in the method for rapid prefabrication of large-size multi-segment concrete immersed pipes in a small dry dock of the present invention is shown in FIG. Figure 5 ;

[0063] In the figure:

[0064] 1. Dry dock; 11. Dock gate; 12. Dock wall; 13. Dock access road; 14. Dock entrance area;

[0065] 21. The first immersed tube prefabrication area; 22. The second immersed tube prefabrication area; 23. The third immersed tube prefabrication area;

[0066] 31. First immersed tube; 32. Second immersed tube; 33. Third immersed tube; 34. Fourth immersed tube; 35. Driving lane; 301. First tube section; 302. Second tube section; 303. Third tube section; 304. Fourth tube section; 305. Fifth tube section;

[0067] 41. Side wall reinforcement binding frame; 42. Top plate reinforcement binding frame; 43. External mold trolley; 43A. First external trolley section; 43B. Second external trolley section; 44. Internal mold trolley; 44A. First internal trolley section; 44B. Second internal trolley section; 45. Middle corridor formwork trolley; 451. Walking beam; 452. Formwork support frame; 45A. First corridor trolley section; 45B. Second corridor trolley section; 45C. Third corridor trolley section; 45D. Fourth corridor trolley section;

[0068] 51. Waterproof bottom steel plate; 52. Bottom plate steel bars; 53. Side wall steel bars; 54. Partition wall steel bars; 55. Top plate steel bars;

[0069] 61. Longitudinal construction channel; 62. Horizontal construction channel;

[0070] 71. Bottom plate; 72. Side wall; 73. Middle wall; 74. Top plate. DETAILED DESCRIPTION

[0071] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0072] In the description of the present invention, it should be understood that the terms "center", "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0073] The terms "first", "second", and "third" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Thus, a feature defined as "first", "second", and "third" may explicitly or implicitly include one or more of the features.

[0074] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0075] like Figure 1 As shown, in an illustrative embodiment of the method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock of the present invention, a first immersed tube prefabrication area 21, a second immersed tube prefabrication area 22 and a third immersed tube prefabrication area 23 are provided at the construction site in the dry dock 1. The first immersed tube prefabrication area 21 and the second immersed tube prefabrication area 22 are both arranged longitudinally and are both located in front of the third immersed tube prefabrication area 23. The third immersed tube prefabrication area 23 is arranged transversely so as to be arranged in a herringbone shape with the first immersed tube prefabrication area 21 and the second immersed tube prefabrication area 22. The dry dock 1 has a dock door 11, and the front end of the first immersed tube prefabrication area 21 faces the dock door 11.

[0076] like Figure 2 As shown, the specific construction steps of the small dry dock large-size multi-segment concrete immersed tube rapid prefabrication construction method are as follows:

[0077] First prefabrication route:

[0078] A first set of prefabrication molds is used to prefabricate multiple pipe sections of the first immersed tube 31 from rear to front starting from the rear end of the first immersed tube prefabrication area 21, and the first set of prefabrication molds is transported from the front end of the first immersed tube prefabrication area 21 to the front end of the second immersed tube prefabrication area 22, and multiple pipe sections of the second immersed tube 32 are prefabricated from front to rear starting from the front end of the second immersed tube prefabrication area 22.

[0079] Second prefabrication route:

[0080] In parallel with the first prefabrication route, a second set of prefabrication molds is used to prefabricate the various tube sections of the third immersed tube 33 starting from one end of the third immersed tube prefabrication area 23 away from the first immersed tube prefabrication area 21 toward the other end.

[0081] Wherein, the prefabricated mold includes a template trolley, and the first set of prefabricated molds further includes a steel bar binding frame.

[0082] After the prefabrication of each pipe segment of the first immersed tube 31 is completed, a wooden form is installed at the post-casting strip between adjacent pipe segments, and concrete is poured in the post-casting strip to connect each pipe segment to form the first immersed tube 31. The second immersed tube 32 and the third immersed tube 33 are connected by post-casting after all the pipe segments are prefabricated to form the second immersed tube 32 and the third immersed tube 33.

[0083] Since the three immersed tube prefabrication areas are arranged in a herringbone shape in the dry dock 1, three longitudinal construction channels 61 are formed on the left and right sides and the middle of the dry dock 1, and three transverse construction channels 62 are formed on the front, middle and rear sides of the dry dock 1.

[0084] The first longitudinal construction channel 61 is composed of the space between the first immersed tube prefabrication area 21 and its adjacent dock wall 12, and the space between one end of the third immersed tube prefabrication area 23 close to the first immersed tube prefabrication area 21 and its adjacent dock wall 12. The second longitudinal construction channel 61 is composed of the space between the second immersed tube prefabrication area 22 and its adjacent dock wall 12, and the space between one end of the third immersed tube prefabrication area 23 close to the second immersed tube prefabrication area 22 and its adjacent dock wall 12. The third longitudinal construction channel 61 is located in the space between the first immersed tube prefabrication area 21 and the second immersed tube prefabrication area 22.

[0085] The first transverse construction channel 62 is composed of the construction area in front of the first immersed tube prefabrication area 21 and the construction area in front of the second immersed tube prefabrication area 22. The second transverse construction channel 62 is composed of the space between the rear end of the first immersed tube prefabrication area 21 and the third immersed tube prefabrication area 23 and the space between the rear end of the second immersed tube prefabrication area 22 and the third immersed tube prefabrication area 23. The third transverse construction channel 62 is composed of the space between the third immersed tube prefabrication area 23 and its adjacent dock wall 12.

[0086] The template trolley includes an inner mold trolley 44 and an outer mold trolley 43. The outer mold trolley 43 has two support frames and a truss installed between the two support frames. In the first prefabrication route, when the outer mold trolley 43 in the first set of prefabrication molds prefabricates each pipe section of the first immersed tube 31, its two support frames move longitudinally in the first longitudinal construction channel 61 and the third longitudinal construction channel 61 respectively; when the outer mold trolley 43 in the first set of prefabrication molds prefabricates each pipe section of the second immersed tube 32, its two support frames move longitudinally in the second longitudinal construction channel 61 and the third longitudinal construction channel 61 respectively. In the second prefabrication route, when the outer mold trolley 43 in the second set of prefabrication molds prefabricates each pipe section of the first immersed tube 31, its two support frames move transversely in the second transverse construction channel 62 and the third transverse construction channel 62 respectively.

[0087] The three transverse construction channels 62 and the three longitudinal construction channels 61 are relatively narrow and can only accommodate one support frame for transverse or longitudinal movement. The transverse construction channel cannot accommodate the support frame on one side of the first set of prefabricated molds and the support frame on one side of the second set of prefabricated molds at the same time in the longitudinal direction, that is, when the support frame on one side of the second set of prefabricated molds is in the second transverse construction channel, the support frame on one side of the first set of prefabricated molds cannot move transversely along the second transverse construction channel and pass over the support frame on one side of the second set of prefabricated molds. The first immersed tube prefabrication area 21 is directly opposite to the dock gate 11. The first immersed tube 31 prefabricated in the first immersed tube prefabrication area 21 needs to be undocking first, that is, the first immersed tube 31 needs to be prefabricated first. While the first immersed tube 31 is being prefabricated, the third immersed tube 33 is being prefabricated in the third immersed tube prefabrication area 23.

[0088] If the first immersed tube prefabrication area 21 is started from the front end, and the pipe sections of the first immersed tube 31 are prefabricated backward, the first set of prefabrication molds will gradually move from the front to the back. When the last pipe section at the rear end of the first immersed tube 31 is prefabricated, the first set of prefabrication molds needs to be transported to the second immersed tube prefabrication area 22. Since the prefabrication molds have a large span and a large weight, and the prefabricated pipe sections have been placed on the first immersed tube prefabrication area 21, if the prefabrication molds are transported across the prefabricated pipe sections to the second immersed tube prefabrication area 22, not only more powerful lifting equipment is required, the cost is higher, and it is difficult to control the hoisting balance of the large-span outer mold trolley 43. The outer mold trolley 43 is easy to lose balance and fall, which not only causes damage to itself, but also smashes the prefabricated pipe sections, so that the pipe sections need to be prefabricated again, which not only causes economic losses, but also prolongs the construction period. In order to avoid the above problems, the first set of prefabrication molds need to be transported horizontally, and the prefabrication molds slightly leave the surface of the dry dock bottom tire area and are transported through the horizontal construction channel 62.

[0089] When the last pipe segment at the rear end of the first immersed tube 31 is prefabricated, the first set of prefabrication molds needs to be transported to the second immersed tube prefabrication area 22 through the second transverse construction channel 62. At the same time, the prefabrication of each pipe segment of the third immersed tube 33 is carried out from one end to the other end of the third immersed tube prefabrication area 23, and the two support frames of the outer mold trolley 43 in the second set of prefabrication molds move transversely in the second transverse construction channel 62 and the third transverse construction channel 62 respectively. At this time, the support frame of the outer mold trolley 43 of the second set of precast molds occupies the second transverse construction channel 62, and the second transverse construction channel 62 can only accommodate one support frame in the longitudinal direction. The transportation of the first set of precast molds will be blocked by the outer mold trolley 43 in the second set of precast molds, and can only be moved to the front end of the first immersed tube prefabrication area 21 and transported to the second immersed tube prefabrication area 22 via the first transverse construction channel 62. However, the trolley and tire frame in the precast mold are large in size, and the steps for moving them are cumbersome. Moving them from the rear end to the front end of the first immersed tube prefabrication area 21 is a long distance. Moving the precast mold to the rear end and transporting it will consume a lot of time, delaying the prefabrication of the second immersed tube 32 in the second immersed tube prefabrication area 22, and extending the construction period.

[0090] In addition, when the second immersed tube prefabrication area 22 completes the prefabrication of each pipe segment from front to back one by one, the second set of prefabrication molds has moved to the end of the third immersed tube prefabrication area 23 away from the second immersed tube prefabrication area 22, thereby avoiding the space between the rear end of the second immersed tube prefabrication area 22 and the third immersed tube prefabrication area 23, so that the first set of prefabrication molds can be transported out of the third immersed tube prefabrication area 23 through the space, so that a shed can be set up for the cast pipe segments in the third immersed tube prefabrication area 23 to carry out post-demolding maintenance of the concrete.

[0091] The first prefabrication route of the present application starts prefabrication from the rear end of the first immersed tube prefabrication area 21. During the prefabrication of the pipe segments one by one, the first set of prefabrication molds first moves forward to move away from the third immersed tube prefabrication area 23, so as to avoid the first set of prefabrication molds entering the second transverse construction channel 62 and hindering the movement of the second set of prefabrication molds, thereby ensuring that the first set of prefabrication molds are smoothly transported to the second immersed tube prefabrication area 22, avoiding mutual interference between the two sets of prefabrication molds, and ensuring that the two prefabrication routes simultaneously prefabricate the pipe segments; and the second set of prefabrication molds in the second prefabrication route gradually move away from the end of the first prefabrication route (i.e., the rear end of the second immersed tube prefabrication area 22), making room for the first set of prefabrication molds to be transported out of the second immersed tube prefabrication area 22, thereby avoiding the prefabrication molds occupying the prefabricated pipe segments and causing a delay in the curing of the concrete after demolding, and finally completing the prefabrication of all required immersed tubes in the shortest construction period.

[0092] The third immersed tube prefabrication area 23 can also prefabricate the fourth immersed tube 34. The fourth immersed tube 34 has only one tube segment, which is arranged in the same straight line as the third immersed tube 33 and is located at one end of the third immersed tube prefabrication area 23 close to the first immersed tube prefabrication area 21. It shares the second set of prefabrication molds with the third immersed tube 33, so that after the prefabrication of each tube segment of the third immersed tube 33 is completed one by one from one end of the third immersed tube prefabrication area 23 close to the second immersed tube prefabrication area 22 to the other end, the fourth immersed tube 34 is further prefabricated, and the prefabrication of the fourth immersed tube 34 is carried out simultaneously with the prefabrication of the second immersed tube 32, which will not increase the construction period of the immersed tube prefabrication.

[0093] The first prefabrication route prefabricates multiple pipe sections in the first immersed tube prefabrication area and multiple pipe sections in the second immersed tube prefabrication area, and the second prefabrication route prefabricates multiple pipe sections in the third immersed tube prefabrication area and one pipe section of the fourth immersed tube. The number of prefabricated pipe sections required for the first prefabrication route is much larger than that required for the second prefabrication route. The prefabrication mold used in the first prefabrication route includes not only the inner mold trolley 44 and the outer mold trolley 43, but also a steel bar binding cradle. When prefabricating the pipe section, the steel bar binding cradle is used to bind the top plate steel bars, thereby completing the steel bar cage of the pipe section, and the outer mold trolley is used to support The support system is converted, so that the steel bar binding frame is withdrawn from the steel bar cage and smoothly sent to the inner mold trolley for subsequent concrete pouring. This prefabrication method does not use the inner mold trolley for top plate steel bar binding, so there is no need to withdraw the inner mold trolley after the concrete solidifies and move it to the next area for top plate steel bar binding of the next pipe section, which improves the efficiency of pipe section prefabrication; the prefabrication mold used in the second prefabrication route only includes the inner mold trolley 44 and the outer mold trolley 43. During prefabrication, the inner mold trolley is used for top plate steel bar binding. After the poured concrete solidifies, the inner mold trolley is withdrawn and moved to the next area. The first prefabrication route adopts an efficient prefabrication method of support system conversion, and the second prefabrication route adopts a prefabrication method of non-support system conversion. The total time consumption of the two prefabrication routes is relatively small, thereby ensuring that all pipe sections can be efficiently prefabricated in the same time period, and the overall prefabrication speed is fast. At the same time, the components of the second set of prefabrication molds are reduced, making the cost investment of immersed tube prefabrication smaller.

[0094] In the above-mentioned exemplary embodiment, in the small dry dock large-size multi-segment concrete immersed tube rapid prefabrication construction method, two prefabrication routes are carried out simultaneously, and multiple immersed tubes are prefabricated at the same time, and the first set of prefabrication molds in the first prefabrication route are first moved in the direction away from the third immersed tube prefabrication area 23, so as to avoid the first set of prefabrication molds and the second set of prefabrication molds from interfering with each other in the narrow space between the first immersed tube prefabrication area 21 and the third immersed tube prefabrication area 23, thereby ensuring that the first set of prefabrication molds are smoothly transported from the first immersed tube prefabrication area to the second immersed tube prefabrication area, ensuring that the two prefabrication routes are synchronized and smoothly carried out in a limited space, with a fast prefabrication speed, shortening the construction period of all immersed tube prefabrication, and the two prefabrication routes use different prefabrication templates, which reduces cost investment, and solves the current problem of short prefabrication period of large-section immersed tubes and narrow prefabrication and circulation areas leading to difficulties in overall planning.

[0095] In some embodiments, Figures 3 to 6 As shown, the multiple pipe sections of the first immersed tube 31 are arranged one by one in sequence from the back to the front, so that the first pipe section 301 of the first immersed tube 31 is located at the rear end.

[0096] In the first prefabrication route step, the second pipe section 302 of the first immersed tube 31 is prefabricated first, then the first pipe section 301 of the first immersed tube 31 is prefabricated, and then the third pipe section 303 of the first immersed tube 31 is prefabricated, and the subsequent pipe sections of the first immersed tube 31 are prefabricated one by one in sequence from back to front.

[0097] When prefabricating the second pipe section 302 of the first immersed tube 31 , the prefabrication molds are assembled one by one at the rear end of the first immersed tube prefabrication area 21 , and the assembled prefabrication molds are transported forward to be used for prefabrication of the second pipe section 302 of the first immersed tube 31 .

[0098] Taking the first immersed tube 31, the second immersed tube 32 and the third immersed tube 33 each having five pipe sections as an example, the first pipe section 301, the second pipe section 302, the third pipe section 303, the fourth pipe section 304 and the fifth pipe section 305 of the first immersed tube 31 are arranged in sequence from back to front, the first pipe section 301, the second pipe section 302, the third pipe section 303, the fourth pipe section 304 and the fifth pipe section 305 of the second immersed tube 32 are arranged in sequence from back to front, and the first pipe section 301, the second pipe section 302, the third pipe section 303, the fourth pipe section 304 and the fifth pipe section 305 of the third immersed tube 33 are arranged in sequence from one end close to the first immersed tube prefabricated area 21 to the other end.

[0099] When the first prefabrication route is used to prefabricate the pipe segments of the first immersed tube 31, the second pipe segment 302 is prefabricated first, and then the first pipe segment 301 is prefabricated, followed by the third pipe segment 303, the fourth pipe segment 304 and the fifth pipe segment 305. After the fifth pipe segment 305 of the first immersed tube 31 is prefabricated, the first set of prefabrication molds is transported from the front end of the first immersed tube prefabrication area 21 to the front end of the second immersed tube prefabrication area 22, and the fifth pipe segment 305 of the second immersed tube 32 is prefabricated first, and then the fourth pipe segment 304, the third pipe segment 303, the second pipe segment 302 and the first pipe segment 301 are prefabricated in sequence.

[0100] When the third immersed tube is prefabricated in the second prefabrication route, the fifth pipe segment 305 of the third immersed tube 33 is prefabricated first, and then the fourth pipe segment 304, the third pipe segment 303, the second pipe segment 302 and the first pipe segment 301 are prefabricated in sequence.

[0101] In the first prefabrication route, the second pipe section 302 of the first immersed tube 31 is prefabricated first. The second pipe section is not located at the end of the immersed tube, and there are fewer embedded parts. Not only is the prefabrication difficulty relatively small, but it is also convenient for prefabrication of subsequent pipe sections and verification of the rationality of each step in the prefabrication process, so that subsequent pipe sections can be prefabricated efficiently and smoothly. Secondly, the second pipe section 302 of the first immersed tube 31 is prefabricated first, and the rear end of the first immersed tube prefabrication area 21 corresponding to the first pipe section 301 of the first immersed tube 31 can be reserved, and the space can be used to assemble the various frames and trolleys in the first set of prefabrication molds. In addition, the jigs and trolleys in the first set of prefabricated molds are assembled one by one, and the assembly sequence matches the construction steps of the pipe segment, that is, when the second pipe segment 302 is prefabricated according to multiple construction steps, the jigs or trolleys required for the next construction step are assembled during the prefabrication in the previous construction step, so that when the next construction step is carried out, the assembly of the corresponding jigs or trolleys has been completed in the adjacent site, and can be directly moved to the construction area of ​​the second pipe segment 302, and utilized for the prefabrication of the second pipe segment 302.

[0102] The rear end of the first immersed tube prefabrication area 21 is reserved as a mold assembly area. The mold assembly area is located in the middle of one side of the dry dock 1. The docking road 13 of the dry dock 1 is also located on the same side, thus being adjacent to the mold assembly area. After the parts required for assembling the mold enter the construction area (first longitudinal construction channel 61) in the dry dock 1 via the docking road 13, they can be delivered to the mold assembly area nearby. The short transportation path improves the speed of the mold assembly operation, thereby ensuring that the prefabrication of all immersed tubes is completed in a shorter construction period.

[0103] Since the second prefabrication route needs to start from the end of the third immersed tube prefabrication area far away from the first immersed tube prefabrication area, it is impossible to assemble the second set of prefabrication molds from this end of the third immersed tube prefabrication area. Therefore, it is necessary to assemble the second set of prefabrication molds at the end of the third immersed tube prefabrication area close to the first immersed tube prefabrication area, and the second set of prefabrication molds only have an outer mold trolley and an inner mold trolley, and the two will not interfere with each other in transportation. In addition, if the first set of prefabrication molds are assembled in the front area of ​​the second pipe section, since the first set of prefabrication molds have a steel bar binding frame, the support system needs to be converted during the prefabrication process, so that each component in the first set of prefabrication molds needs to be used in the prefabrication of the pipe section in sequence, resulting in the subsequent assembly of components will cause transportation obstacles to the components that have been assembled first. Therefore, the first set of prefabricated molds is assembled at the rear end of the first immersed tube prefabrication area, and the second set of prefabricated molds is assembled at one end of the third immersed tube prefabrication area close to the first immersed tube prefabrication area, which can ensure the smooth transfer of the prefabricated molds on the two prefabrication routes and effectively utilize the space at the corner of the dry dock close to the docking road 13. The space is used to assemble the two sets of prefabricated molds at the same time, further improving the efficiency of the prefabrication operation.

[0104] In some embodiments, the steel bar binding frame includes a side wall steel bar binding frame 41 and a top plate steel bar binding frame 42, and the template trolley includes an outer mold trolley 43 and an inner mold trolley 44. The specific steps of prefabrication of the pipe segment are as follows:

[0105] A waterproof bottom steel plate 51 is laid in the dry dock bottom tire area, and the bottom plate rigid frame is installed and the bottom plate reinforcement 52 is tied on the waterproof bottom steel plate 51 .

[0106] The side wall rigid frame and the partition wall rigid frame are installed on the bottom plate rigid frame, and the side wall steel bar tying frame 41 is used to tie the side wall steel bars 53 and the partition wall steel bars 54.

[0107] The top plate rigid frame is installed on the side wall rigid frame and the partition wall rigid frame, and the top plate steel bar tyre 42 is used to tie the top plate steel bar 55.

[0108] The trusses of the outer formwork trolley 43 are connected to the top plate reinforcement 55 through steel strands to complete the conversion of the support system.

[0109] Install tension bolts between the formwork trolleys, install end formwork and embedded steel-edge rubber waterstop, and pour concrete.

[0110] The concrete is cured before demolding. After the curing is completed, the tension bolts are removed and the formwork trolley is used for demolding.

[0111] When the waterproof bottom steel plate 51 is laid on the second pipe section 302 of the first immersed tube 31, the side wall steel bar tying frame 41 is assembled in the rear end area of ​​the first immersed tube prefabrication area 21, so that when the second pipe section 302 is prefabricated in the next step, the side wall steel bar tying frame 41 can be delivered in time to be used for tying the side wall steel bars 53 and the partition wall steel bars 54.

[0112] When the second pipe section 302 of the first immersed tube 31 is tying the side wall reinforcement 53 and the partition wall reinforcement 54, the top plate reinforcement tying frame 42 is assembled in the rear end area of ​​the first immersed tube prefabrication area 21, so that when the second pipe section 302 is prefabricated in the next step, the top plate reinforcement tying frame 42 can be delivered in time and used for tying the top plate reinforcement 55.

[0113] When the top plate reinforcement 55 is being tied to the second pipe section 302 of the first immersed tube 31, the outer formwork trolley 43 is assembled in the rear end area of ​​the first immersed tube prefabrication area 21, so that when the second pipe section 302 is prefabricated in the next step, the outer formwork trolley 43 can be delivered in time to be used for supporting system conversion and as an outer formwork for concrete pouring.

[0114] When the support system of the second pipe section 302 of the first immersed tube 31 is converted, the inner mold trolley 44 is assembled in the rear end area of ​​the first immersed tube prefabrication area 21, so that when the second pipe section 302 is prefabricated in the next step, the inner mold trolley 44 can be delivered in time and used as the inner mold for concrete pouring, so as to enter the subsequent installation and pouring steps as soon as possible.

[0115] Since the prefabrication of the first immersed tube 31 starts from the second pipe section 302, the prefabricated formwork is assembled at the corresponding position of the first pipe section 301. The side wall reinforcement binding frame 41 and the outer formwork trolley 43 in the prefabricated formwork need to utilize the longitudinal construction channels 61 on both sides of the first immersed tube prefabrication area 21, and the top plate reinforcement binding frame 42 and the outer formwork trolley 43 need to occupy the same longitudinal space in the first immersed tube prefabrication area 21. In order to prevent the assembled side wall reinforcement tyre 41 and top plate reinforcement tyre 42 from hindering the longitudinal movement of the outer mould trolley 43 and the inner mould trolley 44 respectively, the first immersed tube 31 sequentially performs the prefabrication process of the second pipe section 302, the first pipe section 301 and the third pipe section 303. After the bottom plate reinforcement 52 of the second pipe section 302 is tied, the third pipe section 303 begins to lay the waterproof bottom steel plate 51. After the side wall reinforcement 53 and the partition wall reinforcement 54 are tied in the second pipe section 302, the side wall reinforcement tyre 41 used in the second pipe section 302 is moved to the third pipe section 303, and the second pipe section 302 is prefabricated. The side wall reinforcement 53 and the partition wall reinforcement 54 of the third pipe segment 303 are tied; after the top plate reinforcement 55 is tied in the second pipe segment 302, the used top plate reinforcement tyre 42 of the second pipe segment 302 is moved to the third pipe segment 303, and the top plate reinforcement 55 of the third pipe segment 303 is tied; then, after the concrete pouring of the first pipe segment 301 is completed, the outer mould trolley 43 is demoulded and moved to the third pipe segment 303 for the support system conversion, and the inner mould trolley 44 is demoulded and moved to the third pipe segment 303, thereby continuing the subsequent steps of prefabrication of the third pipe segment 303 and completing the prefabrication of the third pipe segment 303. For the first pipe segment 301, after all prefabricated molds are prefabricated and moved out of the rear end of the first immersed tube prefabrication area 21, the first pipe segment 301 begins to lay the waterproof bottom steel plate 51 and tie the bottom plate steel bars 52; after the concrete pouring of the second pipe segment 302 is completed, the outer mold trolley 43 is demolded and moved to the first pipe segment 301, and is used to tie the side wall steel bars 53 and the partition wall steel bars 54. The inner mold trolley 44 is demolded and moved to the first pipe segment 301, and is used to tie the top plate steel bars 55. After the steel bars 55 are tied, concrete is directly poured, thereby completing the prefabrication of the first pipe segment 301, and the demolded outer mold trolley 43 and the inner mold trolley 44 are moved to the third pipe segment 303, thereby completing the prefabrication of the third pipe segment 303 after the prefabrication of the first pipe segment 301 is completed.

[0116] When tying the steel bars, the rigid frame is installed and used as support and positioning to improve the stability and accuracy of the steel bar tying. In addition, the rigid frames are installed from bottom to top in sequence, and the rigid frame at the bottom serves as the installation base for the subsequent rigid frames installed above, which improves the position accuracy and stability of the subsequent rigid frames.

[0117] In some embodiments, when the subsequent pipe sections are prefabricated one by one starting from the third pipe section of the first immersed tube 31 in the first prefabrication route step, and when the pipe sections of the third immersed tube 33 are prefabricated one by one from one end to the other end in the second prefabrication route step, when the prefabrication of the previous pipe section proceeds to the tying of the bottom plate steel bars 52, the prefabrication of the next pipe section proceeds to the laying of the waterproof bottom steel plate 51; when the prefabrication of the previous pipe section proceeds to the tying of the side wall steel bars 53, the prefabrication of the next pipe section proceeds to the tying of the bottom plate steel bars 52; when the prefabrication of the previous pipe section proceeds to the tying of the top plate steel bars 55, the prefabrication of the next pipe section proceeds to the tying of the side wall steel bars 53; when the prefabrication of the previous pipe section proceeds to the conversion of the support system, the prefabrication of the next pipe section proceeds to the tying of the top plate steel bars 55.

[0118] Taking the third pipe section 303, the fourth pipe section 304 and the fifth pipe section 305 of the first immersed tube 31 as an example, the third pipe section 303 completes the laying of the waterproof bottom steel plate 51 and enters the bottom plate steel bar 52 plate binding, and the fourth pipe section 304 starts the laying of the waterproof bottom steel plate 51; the third pipe section 303 enters the side wall and partition wall steel bar binding, the fourth pipe section 304 synchronously enters the bottom plate steel bar 52 binding, and the fifth pipe section 305 synchronously starts the laying of the waterproof bottom steel plate 51; the third pipe section 303 enters the top plate steel bar 55 binding, the fourth pipe section 304 synchronously enters the side wall and partition wall steel bar binding, the fifth pipe section 305 synchronously enters the bottom plate steel bar 52 plate binding, and the front end of the second immersed tube 32 construction area synchronously enters the waterproof bottom steel plate 51 laying of the fifth pipe section 305 of the third immersed tube 33. In addition, in order to avoid obstruction to the transportation of the first set of prefabricated molds, after the waterproof bottom steel plate 51 of the fifth pipe section 305 of the third immersed tube 33 is laid, the subsequent prefabrication steps are carried out after the transportation of the first set of prefabricated molds is completed.

[0119] When the prefabrication of pipe segments is carried out one by one from the third pipe segment 303 of the first immersed tube 31 to the fourth pipe segment 304, the subsequent pipe segments and the second immersed tube 32 from front to back, the prefabrication mold can be moved from the previous pipe segment to the next pipe segment one by one, thereby improving the efficiency of the circulation of the prefabrication mold, making the construction steps of two adjacent pipe segments differ by only one step, and the construction steps are more compactly connected, so that the prefabrication of all pipe segments can be completed within a shorter construction period.

[0120] In some embodiments, in the second prefabrication route step, the prefabrication mold used only includes an outer mold trolley 43 and an inner mold trolley 44; the support frames on both sides of the outer mold trolley are used to tie the side wall steel bars and the partition wall steel bars. After the side wall steel bars 53 and the partition wall steel bars 54 are tied, the inner mold trolley 44 is used to tie the top plate steel bars 55.

[0121] The second set of prefabricated molds does not include a template trolley. The support frames on both sides of the outer template trolley are directly used to tie the steel bars of the side walls and partition walls, and the inner template trolley 44 is directly used to tie and support the top plate steel bars 55 without changing the support system. Although the inner template trolley 44 can only be demoulded and moved to the next pipe segment after the concrete of the previous pipe segment is poured and cured, the start time of tying the top plate steel bars 55 of the next pipe segment is relatively delayed. Even if the interval between the completion of prefabrication of adjacent pipe segments in the second prefabrication route is longer, the number of pipe segments required to be prefabricated in the first prefabrication route is greater, and the prefabrication of all pipe segments of the second prefabrication route can be completed within the construction period of the first prefabrication route, saving the cost of the second set of prefabricated molds and improving the economy of the project.

[0122] In some embodiments, when prefabricating the pipe sections at both ends of the immersed tube, the end steel shell is installed after the end template and the embedded steel edge rubber water stop are installed. That is, after the pipe sections at both ends of the immersed tube are installed with the end template and the embedded steel edge rubber water stop, the end steel shell is also installed, so that after the various pipe sections of the immersed tube are assembled, the immersed tube with end steel shells at both ends can be formed, which increases the completion of the immersed tube prefabrication, and enables the immersed tube to be installed underwater after the end template is installed at the port, thereby improving the construction efficiency.

[0123] In some embodiments, the template trolley includes an outer mold trolley 43, and the outer mold trolley 43 is transported from the front end of the first immersed tube prefabrication area 21 to the front end of the second immersed tube prefabrication area 22. Figures 8 to 9 As shown, the specific steps are as follows:

[0124] The outer mold carriage 43 is evenly divided front and back into a first outer carriage portion 43A and a second outer carriage portion 43B.

[0125] The first outer trolley part 43A is moved forward to remove the prefabricated pipe section, and then translated to the front side of the second immersed tube prefabrication area 22, the first outer trolley part 43A is rotated 90 degrees to the longitudinal direction, and is moved to the side of the second immersed tube prefabrication area 22 away from the first immersed tube prefabrication area 21.

[0126] Move the second outer trolley part 43B forward to remove the prefabricated pipe section, and then translate it to the front side of the second immersed tube prefabrication area 22, rotate the second outer trolley part 43B so that one end of it is above the second immersed tube prefabrication area 22 and the other end is between the first immersed tube prefabrication area 21 and the second immersed tube prefabrication area 22, translate it to the rear side of the first outer trolley part 43A and rotate it to the horizontal direction.

[0127] The first outer trolley portion 43A is rotated to the horizontal direction and assembled with the second outer trolley portion 43B at the rear side thereof into an outer mold trolley 43 . The outer mold trolley 43 is moved to the front end of the second immersed tube prefabrication area 22 .

[0128] Since the width of the outer mold trolley 43 in the longitudinal direction is greater than the width of the transverse construction channel 62, the outer mold trolley 43 can be directly moved and abutted against the dock wall 12, and the prefabricated pipe segment cannot be dislodged. The outer mold trolley 43 is split into two parts, and the longitudinal width of each part is reduced, so that it can be translated along the transverse construction channel 62 toward the second immersed tube prefabrication area 22.

[0129] After the outer mold trolley 43 is split, the rear edge of the first outer trolley part 43A cooperates with the front edge of the second outer trolley part 43B, so that the two can be assembled into the outer mold trolley 43 one after the other. If the first outer trolley part 43A and the second outer trolley part 43B are changed to one after the other, it is necessary to rotate the first outer trolley part 43A and the second outer trolley part 43B by 180 degrees. Due to the large span of the immersed tube, the span of the outer mold trolley 43 is further increased. It is very difficult to perform a large-angle rotation on the large span, and the engineering operation is very difficult. Therefore, after the outer mold trolley 43 is disassembled, the first outer trolley part 43A is rotated 90 degrees to the side to make maximum space, so that the second outer trolley part 43B can pass through and move to the rear side of the first outer trolley part 43A with a small tilt. Therefore, after the first outer trolley part 43A and the second outer trolley part 43B are returned to the original position, they are still combined into the outer mold trolley 43 in the same front and back order as the first immersed tube prefabrication area 21, and the rotation range does not exceed 90 degrees during the reverse transportation. In addition, if the number of split parts of the outer mold trolley 43 is larger, due to the large span of a single outer trolley part, if all are rotated and moved to the side, the second longitudinal construction channel 61 cannot be equipped with multiple outer trolley parts longitudinally, and the outer trolley parts rotated to the horizontal direction can only be stacked in the horizontal direction. Since the longitudinal construction channel 61 is narrow, the stacked outer trolley parts extend into the second immersed tube prefabrication area 22, which increases the occupancy of the horizontal space, so that the subsequent outer trolley parts need to be rotated at a larger angle to move to the rear side of the horizontal outer trolley part, and before the rotation, the longer end of the outer trolley part is still on the front side of the front end pipe section of the first immersed tube 31. The large angle rotation can easily cause the outer trolley part to collide with the prefabricated pipe section and the dock wall 12, and multiple outer trolley parts need to be replaced sequentially in the second immersed tube prefabrication area 22 to ensure that they maintain the same front and rear order as the first immersed tube prefabrication area 21, so that the docking parts of adjacent outer trolley parts are opposite to each other and assembled into the outer mold trolley 43. This splitting method increases the number of reverse transportation steps, the movement range and the complexity. Therefore, the present application divides the outer mold trolley 43 into only two parts in equal parts, thereby minimizing the number, movement range and complexity of the transfer steps.

[0130] Dry Dock 1 is equipped with three tower cranes, located in the center of the front end and at the rear of both sides, so as to cover the construction area and transport the mold trolleys.

[0131] In some embodiments, the template trolley includes an inner mold trolley 44, and the inner mold trolley 44 is transported from the front end of the first immersed tube prefabrication area 21 to the front end of the second immersed tube prefabrication area 22. Figures 9 and 10As shown, the specific steps are as follows:

[0132] The inner mold carriage 44 is evenly divided front and back into a first inner carriage portion 44A and a second inner carriage portion 44B.

[0133] The first inner trolley portion 44A is moved forward out of the prefabricated pipe segment and translated into the docking area 14 .

[0134] The second inner trolley portion 44B is moved forward to remove the prefabricated pipe segment, and is translated horizontally and vertically to the front end of the second immersed tube prefabrication area 22 .

[0135] The first inner trolley portion 44A is moved backward out of the dock area 14 , and is translated horizontally and longitudinally to the front end of the second immersed tube prefabrication area 22 , and is further assembled with the second inner trolley portion 44B at the rear side to form the inner mold trolley 44 .

[0136] The width of the inner mold trolley 44 and the outer mold trolley 43 in the longitudinal direction is basically the same, and they are evenly divided into two parts, so that the longitudinal width of each part can be translated to the second immersed tube prefabrication area 22 along the transverse construction channel 62 on the front side. In addition, during the transportation process, the dock area 14 is used to temporarily store the first inner trolley part 44A, and the second inner trolley part 44B is first transported to the second immersed tube prefabrication area 22, and then the first inner trolley part 44A is transported to the second immersed tube prefabrication area 22, so that the first inner trolley part 44A and the second inner trolley part 44B are assembled into the inner mold trolley 44 in the same front and back order as the first immersed tube prefabrication area 21, thereby maintaining the same head-to-tail position relationship as the outer mold trolley 43. In addition, the inner mold trolley 44 is evenly divided into two, so as to avoid too many divisions resulting in the dock area 14 being unable to accommodate the remaining inner trolley parts except the last inner trolley part at the rear end, and causing additional switching of the order between the inner trolley parts during the transportation process.

[0137] A corridor is formed between the two partition walls of the immersed tube, and the template trolley further includes a middle corridor template trolley 45, which has a walking beam 451 arranged in the longitudinal direction and a template support frame 452 that can move forward and backward on the walking beam 451. The template of the corridor is located on the template support frame 452, so that the length of the middle corridor template trolley 45 in the longitudinal direction (approximately equal to the length of the walking beam 451) is greater than or equal to twice that of the inner template trolley 44, and the length of the template support frame 452 is less than half of the walking beam 451. When the middle corridor template trolley 45 is reversed, as shown in FIG. Figure 11 to Figure 12 As shown, follow the steps below:

[0138] The middle corridor template trolley 45 is divided into a first corridor trolley portion 45A, a second corridor trolley portion 45B, a third corridor trolley portion 45C and a fourth corridor trolley portion 45D from front to back.

[0139] The first corridor trolley part 45A, the second corridor trolley part 45B and the third corridor trolley part 45C are integrally moved forward to the front first transverse construction channel 62 , so that the first corridor trolley part 45A and the second corridor trolley part 45B enter the docking area 14 .

[0140] The third corridor trolley part 45C is translated to the side away from the second immersed tube 32 area, the fourth corridor trolley part 45D is translated forward to the first transverse construction channel 62, and the fourth corridor trolley part 45D is translated transversely and longitudinally to the second immersed tube prefabrication area 22 in sequence.

[0141] The third corridor trolley section 45C is sequentially translated horizontally and vertically to the second immersed tube prefabrication area 22, so that it is located in front of the fourth corridor trolley section 45D. The second corridor trolley section 45B is sequentially translated horizontally and vertically to the second immersed tube prefabrication area 22, so that it is located in front of the third corridor trolley section 45C. The first corridor trolley section 45A is sequentially translated horizontally and vertically to the second immersed tube prefabrication area 22, so that it is located in front of the second corridor trolley section 45B.

[0142] The first corridor trolley portion 45A, the second corridor trolley portion 45B, the third corridor trolley portion 45C and the fourth corridor trolley portion 45D are assembled into the middle corridor formwork trolley 45 .

[0143] Since the middle corridor template trolley 45 is relatively long in the longitudinal direction, it is divided into four sections to ensure that it can be transported to the second immersed tube prefabrication area 22 through the first horizontal construction channel 62 when it is translated horizontally. The middle corridor template trolley 45 includes a walking beam 451 and a template support frame 452, and needs to be split into four parts, so that the walking beam 451 is split into four parts, and the template support frame 452 is split into two parts. The two parts of the template support frame 452 are respectively kept installed on the two parts of the corresponding walking beam 451, so that two of the corridor trolley parts include a part of the traveling beam and a part of the template support frame 452. The first corridor trolley part 45A, the second corridor trolley part 45B, the third corridor trolley part 45C and the fourth corridor trolley part 45D are assembled into the middle corridor template trolley 45, the four parts of the walking beam 451 are assembled together, and the two parts of the template support frame 452 are assembled together in a state of being kept installed on the walking beam 451.

[0144] In some embodiments, the steel reinforcement skeleton of the pipe segment is divided into a bottom plate portion 71, two side wall portions 72, two middle wall portions 73 and a top plate portion 74. Figures 13 to 17 As shown in the figure, the specific steps of pouring concrete for the pipe segment are as follows:

[0145] The bottom plate 71 is poured in multiple layers. The two ends and the middle are poured first, and then the remaining part below the roadway 35 is poured. The part of each layer of concrete below the roadway 35 is inclined downward.

[0146] The side wall portion 72 and the middle wall portion 73 are cast in multiple layers.

[0147] The top plate portion 74 is poured in multiple layers, the pouring process is carried out from both ends to the middle, and each layer of concrete poured is inclined downward.

[0148] The concrete pouring of the pipe section is firstly carried out below the four lower chamfers, and then covered layer by layer to the side wall, partition wall and the bottom plate below the roadway 35, so that the part of each layer of concrete on the bottom plate below the roadway 35 is inclined. Due to the large cross-section of the immersed pipe, the horizontal layering requires a large amount of concrete production per unit time. When the number of mixing stations is limited and large-section concrete needs to be iced, the mixing time is extended, and the volume of concrete required for each layer of inclined paving will be less than that for horizontal paving, which is conducive to shortening the time difference between the paving of two layers of concrete, avoiding the occurrence of cold joints, and ensuring that the strength of the large-section immersed pipe meets the requirements.

[0149] The string tube is passed from top to bottom through the two side wall parts 72 and the two middle wall parts 737. When pouring multiple layers below the four chamfers at the bottom, four sky pumps are used to pour concrete into the bottom plate part 71 through the four string tubes at the same time. When pouring the bottom plate below the carriageway 35, the ground pump is directly used to pour the bottom plates of the two carriageways 35 respectively. The four sky pumps are arranged in pairs on both sides of the immersed tube prefabrication area. Each ground pump is equipped with two sets of pump pipes. When pouring the bottom plate below the carriageway 35, the two sets of pump pipes are arranged diagonally in the bottom plate area of ​​the carriageway 35, so that the distribution direction of the concrete is distributed from the two corners of the bottom plate below the carriageway 35 to the middle, ensuring that the concrete layers of the bottom plate below the carriageway 35 are inclined from the outside to the inside and from the bottom to the top, filling the bottom plate part 71 and forming a dense bottom plate.

[0150] The side wall portion 72 and the middle wall portion 73 are simultaneously poured with multiple layers of concrete. The number of layers of concrete in the middle partition wall is greater than that of concrete in the side wall. After the pouring of the side wall portion 72 is completed, there is still a small amount of concrete layer that has not been poured at the top of the middle wall portion 73. At this time, the pouring of the top plate portion 74 is started. The pouring of the two ends of the top plate portion 74 is carried out first, and the pouring of the remaining part of the middle wall portion 73 is completed at the same time, so that the concrete gradually merges with the concrete of the middle partition wall from the two ends of the top plate to the middle, ensuring that the concrete layers on the top plate are inclined, shortening the paving time difference between the two layers of concrete on the top plate, and avoiding cold joints on the top plate.

[0151] Taking the example of concrete being divided into 28 layers, the 1st to 5th layers of concrete are poured on the bottom plate portion 71 below the four lower chamfers; the 6th layer of concrete is poured on the chamfers at the bottom ends of the side walls 72 and the bottom ends of the middle wall portion 73, the 6th to 8th layers of concrete are poured on the bottom plate portion 71 below the carriageway 35, the 8th to 21st layers are poured on the side walls 72, and the 7th to 23rd layers are poured on the middle wall portion 73; after the 21st layer of the middle wall portion 73 is poured, the pouring of the top plate portion 74 is started, and the 22nd to 28th layers are poured in sequence from both ends of the top plate portion 74 to the middle.

[0152] The 22nd layer of concrete of the top plate 74 is further divided into the 22-1, 22-2 and 22-3 layers, and the 23rd layer of the top plate 74 is further divided into the 23-1 and 23-2 layers. In the process of pouring concrete from the 1st layer to the 28th layer, concrete of the same number of layers at different positions is poured in the same time period. The bottom surfaces of the 8th and 28th layers of concrete are both V-shaped.

[0153] The top of the pipe section is chamfered inwards, and the middle partition wall is located in the center of the pipe section, so that the upper load and the top plate load act more on the middle partition wall. The number of concrete layers of the middle wall portion 73 is greater than the number of concrete layers of the side wall portion 72, and the thickness of each layer of concrete on the top of the middle partition wall is less than the thickness of each layer of concrete in the middle and lower parts of the middle partition wall, so that the layering of concrete on the top of the middle partition wall is denser, thereby improving the structural strength of the top of the middle partition wall and the bearing capacity of the pipe section, and ensuring that the immersed tube remains stable under the action of the upper load and the top plate load.

[0154] The thickness of the poured 1st to 5th layers of concrete, as well as the poured 6th and 7th layers of concrete, are all smaller than the thickness of each layer of concrete in the side walls and the thickness of each layer of concrete in the middle and lower parts of the middle partition wall, making the concrete layering of the immersed tube bottom plate denser and stronger, thereby improving the foundation of the immersed tube and enhancing its stability.

[0155] The 22nd layer at both ends of the top plate portion 74 is further divided into three layers to increase the concrete strength at both ends of the top of the pipe segment.

[0156] In some embodiments, the concrete on both sides of the roadway 35 intersects each other.

[0157] In the concrete poured in the bottom plate portion 71, the same number of layers of concrete have a larger pouring volume for a single layer of concrete in the middle of the pipe segment than at both ends of the pipe segment, and the same number of layers of concrete are poured in the same time period, and the bottom plate portion 71 is poured layer by layer in an inclined shape from the bottom of the four chamfers to the bottom of the two lanes 35, and the concrete in the space under each lane 35 converges layer by layer to the center of the space, and the layers of concrete extending from the center of the pipe segment to the outside will flow to the bottom of the center of the lane 35 earlier due to the larger pouring volume, so that this part of the concrete is stacked under the same layer of concrete flowing from the outside to the inside, so that the same layer of concrete is stacked up and down on the left and right sides in sequence, forming a bite of multiple layers of concrete on both sides, thereby improving the structural strength of the bottom plate under the lane 35, so that the subsequent immersed tube can carry a larger traffic volume when used as a tunnel.

[0158] Finally, it should be noted that: the various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0159] The above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or some technical features can be replaced by equivalents without departing from the spirit of the technical solution of the present invention, which should be included in the scope of the technical solution for protection of the present invention.

Claims

1. A method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock, characterized in that: The construction site in the dry dock is provided with a first immersed tube prefabrication area, a second immersed tube prefabrication area and a third immersed tube prefabrication area. The first immersed tube prefabrication area and the second immersed tube prefabrication area are both arranged longitudinally and are both located in front of the third immersed tube prefabrication area. The third immersed tube prefabrication area is arranged transversely so as to be arranged in a herringbone shape with the first immersed tube prefabrication area and the second immersed tube prefabrication area. The dry dock has a dock door, and the front end of the first immersed tube prefabrication area faces the dock door. The specific construction steps are as follows: First prefabrication route: Using a first set of prefabrication molds, starting from the rear end of the first immersed tube prefabrication area, multiple tube sections of the first immersed tube are prefabricated from the rear to the front, and the first set of prefabrication molds are transported from the front end of the first immersed tube prefabrication area to the front end of the second immersed tube prefabrication area, and starting from the front end of the second immersed tube prefabrication area, multiple tube sections of the second immersed tube are prefabricated from the front to the back; Second prefabrication route: In parallel with the first prefabrication route, a second set of prefabrication molds is used to prefabricate the respective tube sections of the third immersed tube starting from one end of the third immersed tube prefabrication area away from the first immersed tube prefabrication area toward the other end thereof; Wherein, the prefabricated mold includes a template trolley, and the first set of prefabricated molds further includes a steel bar binding frame; The multiple pipe sections of the first immersed tube are arranged one by one in sequence from the rear to the front, so that the first pipe section of the first immersed tube is located at the rear end; In the first prefabrication route step, the second pipe section of the first immersed tube is prefabricated first, then the first pipe section of the first immersed tube is prefabricated, and then the third pipe section of the first immersed tube is prefabricated, and the subsequent pipe sections of the first immersed tube are prefabricated one by one in sequence from the back to the front; When prefabricating the second pipe section of the first immersed tube, the prefabrication molds are assembled one by one at the rear end of the first immersed tube prefabrication area, and the assembled prefabrication molds are transported forward to be used for prefabrication of the second pipe section of the first immersed tube.

2. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 1, characterized in that: The steel bar binding frame includes a side wall steel bar binding frame and a top plate steel bar binding frame, the template trolley includes an outer template trolley and an inner template trolley, and the specific steps of prefabrication of the pipe segment are as follows: Lay waterproof bottom steel plates in the dry dock bottom area, install the bottom plate rigid frame and tie the bottom plate reinforcement on the waterproof bottom steel plates; Install the side wall rigid frame and the partition wall rigid frame on the bottom plate rigid frame, and use the side wall steel bar binding frame to bind the side wall steel bars and the partition wall steel bars; Install the top plate rigid frame on the side wall rigid frame and the partition wall rigid frame, and use the top plate steel bar binding frame to bind the top plate steel bars; The trusses of the outer formwork trolley are connected to the top plate reinforcement through steel strands to complete the conversion of the support system; Concrete pouring between the formwork trolleys; Among them, when laying the waterproof bottom steel plate, assemble the side wall steel bar tying frame; when tying the side wall steel bars and partition wall steel bars, assemble the top plate steel bar tying frame; when tying the top plate steel bars, assemble the outer mold trolley; when converting the support system, assemble the inner mold trolley.

3. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 2, characterized in that: When the subsequent pipe sections are prefabricated one by one starting from the third pipe section of the first immersed tube in the first prefabrication route step, and when the pipe sections of the third immersed tube are prefabricated one by one from one end to the other end in the second prefabrication route step, when the prefabrication of the previous pipe section reaches the tying of the bottom plate reinforcement, the prefabrication of the next pipe section proceeds to the laying of the waterproof bottom steel plate; when the prefabrication of the previous pipe section reaches the tying of the side wall reinforcement, the prefabrication of the next pipe section proceeds to the tying of the bottom plate reinforcement; when the prefabrication of the previous pipe section reaches the tying of the top plate reinforcement, the prefabrication of the next pipe section proceeds to the tying of the side wall reinforcement; when the prefabrication of the previous pipe section reaches the tying of the top plate reinforcement, the prefabrication of the next pipe section proceeds to the tying of the side wall reinforcement; when the prefabrication of the previous pipe section reaches the conversion of the support system, the prefabrication of the next pipe section proceeds to the tying of the top plate reinforcement.

4. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 2, characterized in that: In the second prefabrication route step, the prefabrication mold used only includes an outer mold trolley and an inner mold trolley; the support frames on both sides of the outer mold trolley are used to tie the side wall reinforcement and the partition wall reinforcement. After the side wall reinforcement and the partition wall reinforcement are tied, the inner mold trolley is used to tie the top plate reinforcement.

5. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 2, characterized in that: When prefabricating the pipe sections at both ends of the immersed tube, the end formwork and the embedded steel-edged rubber waterstop are installed between the formwork trolleys after the support system is converted, and then the end steel shell is further installed.

6. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 1, characterized in that: The template trolley includes an outer template trolley, and the outer template trolley is transported from the front end of the first immersed tube prefabrication area to the front end of the second immersed tube prefabrication area. The specific steps are as follows: The outer mold trolley is evenly divided into a first outer trolley part and a second outer trolley part front and back; The first outer trolley is moved forward to remove the prefabricated pipe section, and then translated to the front side of the second immersed tube prefabrication area, the first outer trolley is rotated 90 degrees to the longitudinal direction, and is moved to the side of the second immersed tube prefabrication area away from the first immersed tube prefabrication area; The second outer trolley is moved forward to remove the prefabricated pipe section, and then translated to the front side of the second immersed tube prefabrication area, and the second outer trolley is rotated so that one end of the second immersed tube prefabrication area is above the second immersed tube prefabrication area and the other end is between the first immersed tube prefabrication area and the second immersed tube prefabrication area, and then translated to the rear side of the first outer trolley and rotated to the horizontal direction; The first outer trolley portion is rotated to the horizontal direction and assembled with the second outer trolley portion at the rear side to form an outer mold trolley, and the outer mold trolley is moved to the front end of the second immersed tube prefabrication area.

7. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 6, characterized in that: The template trolley includes an inner mold trolley, and the inner mold trolley is transported from the front end of the first immersed tube prefabrication area to the front end of the second immersed tube prefabrication area. The specific steps are as follows: The inner mold trolley is evenly divided into a first inner trolley part and a second inner trolley part front and back; The first inner carriage part is moved forward to remove the prefabricated pipe segment and horizontally moved to the docking area; The second inner trolley is moved forward to remove the prefabricated pipe segment, and is translated horizontally and vertically to the front end of the second immersed tube prefabrication area; The first inner trolley portion is moved backward out of the dock area, and is translated horizontally and vertically to the front end of the second immersed tube prefabrication area, and is further assembled with the second inner trolley portion at the rear side to form an inner mold trolley.

8. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 1, characterized in that: The steel skeleton of the pipe segment is divided into a bottom plate, two side walls, two middle walls and a top plate. The specific steps for pouring concrete for the pipe segment are as follows: The bottom plate is poured in multiple layers. The two ends and the middle are poured first, and then the remaining part under the roadway is poured. The part of each layer of concrete poured under the roadway is inclined downward. Multi-layer pouring of side walls and middle walls; The top plate is poured in multiple layers from both ends to the middle, and each layer of concrete is poured with a downward slope.

9. The method for rapid prefabrication of large-size multi-segment concrete immersed tubes in a small dry dock according to claim 8, characterized in that: The concrete on both sides of the carriageway cross each other.

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