Shaped steel mold pumping concrete super high cast-in-situ vase-shaped piers and construction method

Abstract

The application provides a shaped steel mold pumping concrete super-high cast-in-situ vase column and a construction method, which comprises the following steps: pre-processing the reinforcing steel bars by using a continuous bending machine; designing and manufacturing a whole binding jig frame of the column body reinforcing steel bars; accurately lofting the column body axis and contour line and binding the column body embedded reinforcing steel bars; improving the whole lifting device of the reinforcing cage; manufacturing and installing the assembled ladder cage operation platform; the construction method has the characteristics of simple and convenient reinforcing steel bar bending operation, high precision, stable lifting device, convenient precast ladder cage installation and removal, convenient curve segment reinforcing steel bar binding and the like. The application is suitable for super-high cast-in-situ vase column engineering.

Description

Technical Field

[0001] This invention relates to the field of vase-shaped pier construction, and in particular to ultra-high cast-in-place vase-shaped piers constructed using prefabricated steel molds and pumped concrete, and their construction methods. Background Technology

[0002] With the rapid development of highway bridge construction and the increasing demands for harmony with the surrounding environment, aesthetic requirements are becoming more stringent. Vase-shaped piers, due to their attractive appearance, are increasingly being adopted in the design of highway bridges around cities. However, the construction speed of vase-shaped piers using traditional construction techniques is slow due to several factors: ① The irregular and complex arrangement of steel reinforcement in vase-shaped piers leads to low efficiency in traditional steel reinforcement fabrication methods; ② On-site installation of steel reinforcement is difficult, installation accuracy is hard to control, and errors are prone to occur; ③ The current conventional construction method for bridge piers is a combination of steel formwork and double-row steel pipe temporary scaffolding. Because the formwork and construction platform are independent systems, repeated installation and dismantling are required, leading to resource waste and construction delays; ④ For taller vase-shaped piers, the dense steel reinforcement inside and at the top prevents workers from entering the pier body for concrete vibration, requiring multiple pouring processes. This process is not only slow but also prone to defects such as concrete misalignment and color differences. Summary of the Invention

[0003] The purpose of this invention is to provide a fixed steel mold pumped concrete ultra-high cast-in-place vase pier and construction method to solve the above-mentioned technical problems.

[0004] To solve the above-mentioned technical problems, the present invention provides a construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete, comprising the following steps:

[0005] S1. Pre-processing of steel bars using a continuous bending machine: The steel bars to be processed are placed on the workbench. After the steel bars are fixed by the adjustable positioning rollers and the positioning rollers, the first positioning roller and the second positioning roller act on the steel bars to be processed, so that the steel bars are bent. After the given arc requirement is reached, the steel bars to be processed are bent in the opposite direction. The second positioning roller or the first moving positioning roller acts on the steel bars to be processed, so that they are bent in the opposite direction. When the required arc is reached to form a prefabricated semi-finished steel bar, the moving positioning power mechanism stops.

[0006] S2. Design and fabricate the overall binding frame for the pier body reinforcement: connect the prefabricated semi-finished steel bars to the legs and diagonal braces; connect the legs and diagonal braces in sequence according to the diagonal principle, and then arrange the horizontal and vertical spacing of the legs;

[0007] S3. Accurately lay out the axis and outline of the pier body, and tie the pre-embedded steel bars of the pier body: The pier body formwork adopts integral rigid formwork, and the interior of the integral rigid formwork is lined with waterproof formwork cloth. The front and side formwork is tightened with corner tie rods.

[0008] S4. Improved overall hoisting device for steel cage: First, install guy ropes on the main body of the vase pier; the object to be hoisted is fixed to the hoisting rod by a fixed cable and a fixed rod, and the two ends of the fixed rod and the hoisting rod are connected between the two guy ropes by lifting rings, so that the object to be hoisted can be transported along the direction of the guy ropes; finally, connect the hoisting rod and the hoisting rope to the hoisting equipment for hoisting operation.

[0009] S5. Fabrication and Installation of Prefabricated Ladder Cage Operating Platform: The prefabricated ladder cage operating platform is installed between the lower and upper supports. First, embedded parts are arranged on the lower support, then the pier body is fixed, and then protective plates are installed to form the prefabricated ladder cage operating platform. On the outer perimeter of the pier body, uprights, horizontal tie rods and diagonal tie rods are connected by disc-type buckles to form the skeleton of the prefabricated ladder cage operating platform, and finally the construction of the prefabricated ladder cage operating platform is completed.

[0010] The beneficial effects of this invention are as follows:

[0011] (1) The present invention uses a continuous bending machine during steel bar processing, which can preset the steel bar curvature. After one bending, the next reverse bending curvature can be set directly, which improves the steel bar processing accuracy and efficiency. At the same time, the upper platform of the bending machine is equipped with a limiting device to prevent the steel bar from coming out during the bending process.

[0012] (2) The present invention solves the binding problem in the process of binding the reinforcing bars in the curved section by using the overall binding frame device for the pier body;

[0013] (3) The present invention adopts an improved steel cage hoisting device to ensure the vertical stability of the steel cage during hoisting, eliminates the step of manually tensioning the guy ropes, reduces labor costs, improves wind resistance performance, and helps to improve construction efficiency.

[0014] (4) This invention adopts a prefabricated ladder cage operating platform, with standardized components that facilitate transportation and management; the prefabricated structure has no loose or easily lost components, resulting in low loss. The cost of each assembly and disassembly is half that of other types of ladders, and it can be hoisted as a whole, which greatly improves construction efficiency, increases the reuse rate, and has significant overall benefits. Attached Figure Description

[0015] Figure 1 This is a top view of the continuous bending machine.

[0016] Figure 2 This is a schematic diagram of the transverse cross-sectional structure of the overall binding frame.

[0017] Figure 3 This is a schematic diagram of the longitudinal cross-sectional structure of the overall binding frame.

[0018] Figure 4 This is a top view of the integral vase-shaped support frame template.

[0019] Figure 5 A schematic diagram of the main view structure of the improved overall hoisting device for steel cages.

[0020] Figure 6 This is a schematic diagram of the side elevation structure of the prefabricated ladder cage operating platform.

[0021] In the diagram: 1-Operating platform; 2-Positioning roller; 3-Adjustable positioning roller; 4-First moving positioning roller; 5-Second moving positioning roller; 6-Support track; 7-Moving positioning roller support; 8-Support plate; 9-Adjusting rod; 10-Adjusting nut; 11-Feeding roller; 12-Pressure roller; 13-Pressure roller support; 14-Hydraulic cylinder; 15-Hydraulic cylinder support; 16-Restriction structure; 17-Outrigger; 18-Diagonal brace; 19-Outrigger support; 20-Integral rigid template; 21-Angle tie rod; 22-Vase-shaped pier panel template; 23 - Vertical stiffening rib; 24- Horizontal rib; 25- Guy rope; 26- Fixing rod; 27- Fixing lock; 28- Lifting ring; 29- Counterweight; 30- Lifting rod; 31- Lifting rope; 32- Lifted object; 33- Safety rope; 34- Upper support; 35- Lower support; 36- Prefabricated ladder cage operating platform; 37- Ladder; 38- Upright pole; 39- Horizontal tie rod; 40- Diagonal tie rod; 41- Buckle; 42- Protective plate; 43- Support railing; 44- Horizontal connecting rod; 45- Adjustable bottom support; 46- Adjustable top support; 47- Diagonal brace. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0023] Those skilled in the art should understand that, in the disclosure of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the above terms should not be construed as limiting this invention.

[0024] It is understood that the term "a" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple, and the term "a" should not be understood as a limitation on the number.

[0025] like Figures 1-6 The present invention provides a prefabricated steel mold pumped concrete ultra-high cast-in-place vase-shaped pier and a construction method thereof, including the following steps:

[0026] S1. Pre-processing of reinforcing bars using a continuous bending machine: The reinforcing bars to be processed are placed on the workbench 1. After being fixed by adjustable positioning rollers 3 and 2, the first positioning roller 4 and the second positioning roller 5 act on the reinforcing bars to be bent according to the original bending arc. After reaching the given arc requirement, the reinforcing bars are bent in the opposite direction by applying the second positioning roller 5 or the first moving positioning roller 4 to the reinforcing bars to be bent in the opposite direction. When the required arc is reached and a pre-fabricated semi-finished reinforcing bar is formed, the moving positioning power mechanism stops operating. This achieves automated multi-segment bending of reinforcing bars.

[0027] The continuous bending machine's worktable is equipped with a support rail 6, and the support rail 6 has a movable positioning roller bracket 7. The adjustable positioning roller 3 is fixed to the movable positioning roller bracket 7 by a pin. The moving positioning power mechanism includes several rotating feeding rollers 11 and pressing rollers 12. The feeding rollers 11 and pressing rollers 12 are fixed to both sides of the rebar to be processed. The pressing rollers 12 are fixed to the pressing roller bracket 13. A hydraulic cylinder 14 and a hydraulic cylinder bracket 15 are fixed to the lower part of the pressing roller bracket 13. The upper part of the platform is equipped with a horizontally extending limiting mechanism 16. The limiting mechanism 16 is located above the rebar to be processed and is used to limit the position of the rebar to prevent it from coming off upwards.

[0028] The workbench 1 has a support plate 8 on one side of the adjustable positioning wheel 3. An adjusting rod 9 is movably mounted on the support plate 8. An adjusting nut 10 is fitted on one side of the adjusting rod 9, and the adjusting rod 9 and the adjusting nut 10 are threaded together so that the adjusting nut 10 positions the adjusting rod 9, thereby ensuring the stable positioning of the adjustable positioning wheel 3 on the reinforcing bar.

[0029] Specifically, after the adjustable positioning roller 3 and positioning roller 2 have positioned the reinforcing bar, the first positioning roller 4 and the second positioning roller 5 move to push the reinforcing bar, causing the reinforcing bar to bend to one side, so as to control the bending angle and direction of the reinforcing bar. The first positioning roller 4 and the second positioning roller 5 can be controlled by a hydraulic cylinder to move.

[0030] S2. Design and fabricate the overall binding frame for the pier reinforcement: Process and weld the prefabricated semi-finished steel bars according to the drawings. First, weld the support leg 17 to the diagonal brace 18. Weld the support leg 17 to the diagonal brace 18 in sequence according to the diagonal principle. Then arrange the horizontal and vertical spacing of the support leg 17 and start welding the reinforcement bars in different directions. The frame structure is then completed.

[0031] The pier reinforcement integral binding frame includes several legs 17 and diagonal braces 18. The legs 17 are evenly spaced in the horizontal and vertical directions to form a support structure. The legs descend at the same height in the longitudinal direction, and their stroke matches the curvature of the pier column. Adjacent legs in the longitudinal and horizontal directions are reinforced and fixed by diagonal braces 18. The diagonal braces 18 are arranged in a crisscross pattern, and a leg support part 19 is set at the intersection of the diagonal braces 18.

[0032] S3. Accurately lay out the axis and outline of the pier body, and tie the pre-embedded steel bars of the pier body: The pier body formwork adopts the integral rigid formwork 20, and the interior of the integral rigid formwork 20 is covered with waterproof formwork cloth. The front and side formwork is tightened by 32 diagonal tie rods 21; the vase pier panel formwork 22 adopts ordinary 6mm steel plate, the vertical stiffening ribs 23 adopt 12mm channel steel, and the horizontal ribs 24 adopt 25mm channel steel.

[0033] The integral rigid formwork is divided into 20 blocks according to the cross-sectional shape, and the overall structural form is a stiffened panel back truss. The upper and lower layers of formwork are connected by positioning pins, and the front formwork and the side formwork are tightened at both ends by Φ32mm diagonal tie rods 21.

[0034] S4. Improved overall hoisting device for steel cage: First, install guy ropes 25 on the main body of the vase pier; the hoisting object 32 is fixed to the lifting rod 30 by the fixed cable 27 and the fixed rod 26. The two ends of the fixed rod 26 and the lifting rod 30 are connected between the two guy ropes 25 by the lifting rings 28 so that the hoisting object 32 can be transported along the direction of the guy ropes 25; finally, connect the lifting rod 30 and the lifting rope 31 to the hoisting equipment for hoisting operation.

[0035] The improved steel cage hoisting device includes guy ropes 25, fixed rods 26, fixed slings 27, lifting rings 28, counterweights 29, lifting rods 30, and lifting ropes 31. The upper parts of the two guy ropes 25 are fixed to the upper part of the vase-shaped pier, and the lower ends of the two guy ropes 25 are suspended from the counterweights 29, making the guy ropes 25 vertical. The fixed slings 27 are connected to the fixed rods 26 and the lifting rods 30 through the lifting rings 28, and the other end of the fixed slings 27 is connected to the hoisting object 32 through the lifting rings 28.

[0036] The connection between the lifting boom 30 and the lifting rope 31 is connected to the connection between the fixed sling 27 and the hoisting object 32 via a safety rope 33, so as to improve the hoisting stability of the hoisting object 32.

[0037] S5. Fabrication and Installation of Prefabricated Cage Operating Platform 36: The prefabricated cage platform is installed between the lower support 35 and the upper support 34. First, embedded parts are arranged on the lower support 35, then the pier body is fixed. Next, protective plates 42 are installed to form the prefabricated cage operating platform 36. The uprights 38, horizontal tie rods 39, and diagonal tie rods 40 are connected to the outer perimeter of the pier body using disc-type buckles 41 to form the skeleton of the prefabricated cage operating platform 36. Finally, the construction of the prefabricated cage operating platform 36 is completed.

[0038] The lower support 35 is connected and fixed to the cantilevered bottom of the prefabricated ladder cage operating platform 36 by diagonal bracing 47. The prefabricated ladder cage operating platform 36 contains a ladder 37 and also includes uprights 38 mounted on the lower support 35. Several parallel horizontal tie rods 39 and diagonal tie rods 40 are provided between adjacent uprights 38. The two ends of the diagonal tie rods 40 are connected to the ends of two horizontal tie rods 39 at different heights. The top of the uprights 38 is provided with a protective plate 42, and the upper support 34 is provided with a support railing 43. The support railing 43 is fixed to the upper support 34 by a horizontal connecting rod 44. The bottom of the uprights 38 is provided with several adjustable base supports 45, and the top of all uprights 38 is provided with an adjustable top support 46.

[0039] This invention is not limited to the preferred embodiments described above. Anyone can derive other products in various forms under the guidance of this invention. However, regardless of any changes in shape or structure, any technical solution that is the same as or similar to this application falls within the protection scope of this invention.

Claims

1. A construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete, characterized in that... Includes the following steps: S1. Pre-processing of steel bars using a continuous bending machine: Place the steel bars to be processed on the workbench (1), fix the steel bars to be processed by the adjustable positioning roller (3) and the positioning roller (2), and then apply the first positioning roller (4) and the second positioning roller (5) to the steel bars to be processed to bend the steel bars. After reaching the given arc requirement, the steel bars to be processed are bent in the opposite direction. Apply the second positioning roller (5) or the first moving positioning roller (4) to the steel bars to be processed to bend them in the opposite direction. When the required arc is reached and a pre-made semi-finished steel bar is formed, the moving positioning power mechanism stops operating. S2. Design and manufacture the pier body steel reinforcement binding frame: connect the prefabricated semi-finished steel reinforcement to the support legs (17) and the diagonal braces (18); connect the support legs (17) and the diagonal braces (18) in sequence according to the diagonal principle, and then arrange the horizontal and vertical spacing of the support legs (17). S3. Accurately lay out the axis and outline of the pier body, and tie the pre-embedded steel bars of the pier body: The pier body formwork adopts an integral rigid formwork (20), the interior of the integral rigid formwork (20) is covered with waterproof formwork cloth, and the front and side formwork is tightened by angle tie rods (21); S4. Improved steel cage hoisting device: First, install guy ropes (25) on the main body of the vase pier; the hoisting object (32) is fixed to the lifting rod (30) by the fixed cable (27) and the fixed rod (26). The two ends of the fixed rod (26) and the lifting rod (30) are connected between the two guy ropes (25) by the lifting rings (28), so that the hoisting object (32) can be transported along the direction of the guy ropes (25); finally, connect the lifting rod (30) and the lifting rope (31) to the hoisting equipment for hoisting operation. S5. Fabrication and installation of prefabricated ladder cage operating platform (36): The prefabricated ladder cage operating platform (36) is installed between the lower support (35) and the upper support (34). First, embedded parts are arranged on the lower support (35), then the pier body is fixed, and then the protective plate (42) is installed to form the prefabricated ladder cage operating platform (36). The uprights (38), horizontal tie rods (39) and diagonal tie rods (40) are connected to the outer periphery of the pier body through disc-type buckles (41) to form the skeleton of the prefabricated ladder cage operating platform (36). Finally, the prefabricated ladder cage operating platform (36) is erected.

2. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: The workbench (1) is provided with a support rail (6), and there is a movable positioning roller bracket (7) on the support rail (6). The adjustable positioning roller (3) and the movable positioning roller bracket (7) are fixed by a pin.

3. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: The moving positioning power mechanism includes several rotating feeding rollers (11) and pressing rollers (12). The feeding rollers (11) and pressing rollers (12) are fixed on both sides of the steel bar to be processed. The pressing rollers (12) are fixed on the pressing roller bracket (13). The pressing roller bracket (13) has a hydraulic cylinder (14) and a hydraulic cylinder bracket (15) fixed at the lower part. The upper part of the worktable (1) is provided with a limiting mechanism (16) that can extend in the horizontal direction. The limiting mechanism (16) is located on the upper side of the steel bar to be processed and is used to limit the position of the steel bar.

4. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: A support plate (8) is provided on one side of the adjustable positioning wheel (3) on the workbench (1). An adjusting rod (9) is movably provided on the support plate (8). An adjusting nut (10) is sleeved on one side of the adjusting rod (9), and the adjusting rod (9) and the adjusting nut (10) are threaded together so that the adjusting nut (10) positions the adjusting rod (9).

5. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: Adjacent legs are fixed together by diagonal braces (18), the diagonal braces (18) are arranged in a cross pattern, and a leg support part (19) is provided at the intersection of the diagonal braces (18).

6. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: The upper part of the guy rope (25) is fixed to the upper part of the vase pier, and the lower end of the guy rope (25) is suspended by a counterweight (29) to make the guy rope (25) vertical; the fixed sling (27) is connected to the fixed rod (26) and the lifting rod (30) through the lifting ring (28), and the other end of the fixed sling (27) is connected to the object being lifted (32) through the lifting ring (28).

7. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: The connection between the lifting rod (30) and the lifting rope (31) is connected to the connection between the fixed sling (27) and the object being lifted (32) via a safety rope (33).

8. The construction method for ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete according to claim 1, characterized in that: The lower support (35) is connected and fixed to the cantilevered bottom of the prefabricated ladder cage operating platform (36) by an inclined brace (47); the prefabricated ladder cage operating platform (36) has a ladder (37) inside, and the two ends of the inclined tie rod (40) are connected to the ends of two horizontal tie rods (39) of different heights; the top of the upright (38) is provided with a protective plate (42), the upper support (34) is provided with a support railing (43), the support railing (43) is fixed to the upper support (34) by a horizontal connecting rod (44), the bottom of the upright (38) is provided with several adjustable base supports (45), and the top of all uprights (38) is provided with an adjustable top support (46).

9. A type of prefabricated steel mold pumped concrete ultra-high cast-in-place vase-shaped pier, characterized in that: The method for constructing ultra-high cast-in-place vase-shaped piers using prefabricated steel molds and pumped concrete, as described in any one of claims 1-8, was used.

Images