Rapid mechanical breaking device and method for pile head of cast-in-place pile

Abstract

The invention discloses a rapid mechanical breaking device and method for a cast-in-place pile head, the device comprises a polisher, a small drilling machine, a pile breaking machine and a hydraulic shear, the polisher is used for polishing the pile head to find out the position of a main reinforcement, the small drilling machine is used for drilling to assist the pile breaking machine in positioning, and double drill bits of the pile breaking machine crush concrete inside and outside to form a hollow cylinder wall; and the hydraulic shear crushes the cylinder wall concrete and peels the main reinforcements to realize efficient breaking of the pile head. The operation method comprises the following steps: firstly, polishing a pile head by using a polisher, marking the position of a main reinforcement and determining a pile head center positioning point; then, a hole is drilled in the center point so as to assist the pile breaking machine in accurate positioning; then, the pile breaking machine rotates at a high speed and presses downwards, cutting teeth at the bottom ends of double drill bits of the pile breaking machine crush the concrete under the action of rotary cutting force, and a hollow cylindrical outer wall is formed; and finally, the outer wall concrete is sheared, pressed and crushed by a hydraulic shear to strip out main reinforcements, and pile head breaking is completed after cleaning. Compared with a traditional manual air pick breaking mode, the multi-machine cooperation greatly improves the construction efficiency and safety, is especially suitable for breaking pile heads of large-diameter cast-in-place piles, remarkably reduces the construction cost and improves the operation efficiency and precision.

Description

Technical Field

[0001] The invention relates to the field of pile foundation construction and is a device and method for quickly mechanically breaking the pile head of a bored pile, which is particularly suitable for scenes where there is a lack of manpower and the bored pile, especially the concrete of the pile head of a large-diameter bored pile, needs to be quickly broken. Background Art

[0002] As an important form of deep foundation engineering, the construction quality of bored piles directly affects the stability of the superstructure. During the concrete pouring stage, over-pouring is a key link to ensure the integrity and quality of the pile body. Since the mud wall in the pile hole can easily cause the concrete to mix with impurities and suspend in the upper layer of concrete, the relevant design specifications usually require that the concrete pouring height exceed the pile foundation design elevation by more than 0.8m. This technical measure can effectively compensate for the drop in the concrete liquid level, avoid defects such as mud and honeycombs on the pile top caused by floating or shrinking sediment, and ensure that the strength of the pile top meets the design requirements. The control of over-pouring volume needs to be combined with geological conditions, pile diameter and construction technology. Excessive over-pouring will increase costs, and insufficient over-pouring may cause the risk of broken piles.

[0003] Pile head removal is an indispensable process after pile construction, and it is mainly used to deal with the over-filled concrete. Since the concrete in the over-filled section is in contact with mud for a long time, it is easy to be mixed with sediments inside, and the mechanical properties are significantly reduced, so it needs to be completely removed to the designed elevation. During the removal process, it is necessary to focus on protecting the integrity of the pile body. Usually, a process combining circumferential cutting and mechanical crushing is adopted: first, the cutting machine is used to cut into the steel bar protective layer at the designed elevation of the pile head, and then the concrete is peeled off with a pneumatic pick, and finally the concrete block of the pile head is lifted off. This process requires precise control of the removal depth to avoid damage to the main reinforcement or pile body structure, while ensuring that the length of the exposed steel bar meets the specification requirements for subsequent abutment connection.

[0004] There are many disadvantages in manually using pneumatic picks to break the pile heads of cast-in-place piles. First, the labor intensity is high and the construction speed is slow, especially when dealing with large-diameter or high-strength pile heads. Secondly, the noise and dust generated during the operation of the pneumatic pick pose a threat to the health of construction workers and surrounding residents. Furthermore, improper operation can easily cause damage to the pile body, affecting the bearing capacity and stability of the pile body. At the same time, it is difficult to accurately control the strength and direction of manual operation, which can easily damage the steel bars and reduce the connection strength of the pile head.

[0005] The advantages of mechanical methods for breaking pile heads are mainly reflected in high efficiency, safety, and environmental protection. Mechanical breaking is fast and can greatly improve construction efficiency; at the same time, remote control can reduce the risk of manual construction and ensure the safety of personnel; in addition, mechanical breaking can also reduce noise and dust pollution, which is more in line with the requirements of green construction. Summary of the invention

[0006] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: the present invention relates to a device and method for rapid mechanical breaking of cast-in-place pile heads, which has the following innovative features: the device adopts a multi-mechanical collaborative operation system, including four core components: a grinder, a small drilling rig, a pile breaker and a hydraulic shear.

[0007] The bottom of the grinder adopts a flat plate design with wear-resistant high-strength alloy cutting teeth. It rotates and presses down to cut the pile head concrete until the main reinforcement is exposed, and uses cross-line markings to accurately locate the center of the pile head.

[0008] The small drilling rig provides a guide reference for the pile breaker by pre-drilling the center positioning hole to ensure operation accuracy.

[0009] The pile breaker is innovatively equipped with an inner and outer double drill bit structure. The outer drill bit uses cutting teeth to achieve straightening guidance and peripheral crushing, while the inner drill bit crushes the central concrete through high-speed spinning to form a hollow cylindrical outer wall.

[0010] The hydraulic shears are equipped with an adjustable angle shearing and compression structure, which can adapt to pile heads of different sizes, efficiently remove the concrete around the main reinforcement, and quickly peel off the main reinforcement.

[0011] The picks of each device are made of replaceable wear-resistant alloy material, which significantly increases the service life.

[0012] Furthermore, the implementation steps adopted by the present invention are: First, use a grinder to grind the surface of the pile head and smooth the concrete layer of the pile head until the main reinforcement is exposed. At the same time, mark the center position of the pile head with a cross of the main reinforcement to ensure the accuracy of subsequent operations.

[0013] Then, a small drilling rig is used to drill a positioning hole in the center of the pile head. The hole can be used as a guide reference for the pile breaker drill bit to improve the stability and accuracy of the crushing operation.

[0014] Next, the pile breaker uses the inner and outer double drill bits to break the concrete at the pile head. After the pile breaker is started, the outer drill bit straightens the guide and breaks the outer concrete, while the inner drill bit breaks the concrete at the center of the pile head at high speed under the action of the rotary shear force, eventually forming a hollow cylindrical outer wall, making the pile breaking process more efficient.

[0015] Subsequently, hydraulic shears are used to shear and crush the remaining cylindrical outer wall concrete. The hydraulic shears have a structure with adjustable shear angles and can adapt to pile heads of different sizes and shapes, ensuring that the concrete is completely broken while the main reinforcement is quickly stripped off without physical damage.

[0016] Finally, the debris and residual concrete around the pile head are cleaned to ensure that the main reinforcement of the pile head is intact, and finally the rapid mechanical breaking operation of the pile head is completed. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0018] Figure 1 It is a three-dimensional schematic diagram of a device and method for quickly mechanically breaking a pile head of a bored pile according to the present invention, after a grinder grinds the pile head flat to expose the main reinforcement of the bored pile and marks the center positioning point; Figure 2 It is a three-dimensional schematic diagram of a device and method for quickly mechanically breaking a cast-in-place pile head according to the present invention after a positioning hole is drilled by a small drilling rig; Figure 3 It is a three-dimensional schematic diagram of a device and method for quickly mechanically breaking a cast-in-place pile head according to the present invention, after a pile breaker breaks concrete to form a hollow cylindrical outer wall; Figure 4 It is a three-dimensional schematic diagram of a device and method for quickly mechanically breaking a cast-in-place pile head according to the present invention, in which the outer wall concrete around the main reinforcement is crushed by hydraulic shears after the main reinforcement is peeled off; Figure 5 The present invention is a flowchart of the implementation of a device and method for rapid mechanical breaking of a cast-in-place pile head.

[0019] In the figure: the device is composed of a grinder (1), a small drilling machine (2), a pile breaker (3) and a hydraulic shear (4) and works together, and also involves a cast-in-place pile head (5) that needs to be broken.

[0020] like Figure 1 As shown, the bottom end of the grinder (1) is a flat surface (11) and a pick (12) is embedded in the bottom. The concrete of the pile head (5) is cut by rotating and pressing down until the main reinforcement (51) is exposed, and the center position (53) of the pile head (5) is marked by the cross elasticity (52) of the main reinforcement.

[0021] like Figure 2 As shown, the small drilling machine (2) drills a positioning hole (54) at the central position (53) of the pile head (5) to ensure that the pile breaker (3) does not deviate when hollowing out the concrete in the center of the pile head (5), and the operation accuracy is improved through the guidance of the hole (54).

[0022] like Figure 3 As shown, the pile breaker (3) is provided with a double drill bit for rotary pile breaking: an inner drill bit (31) and an outer drill bit (32). The inner drill bit (31) and the outer drill bit (32) are both provided with pick teeth (33) at their bottom ends. An observation hole (321) is provided on the wall of the outer drill bit (32). The outer drill bit (32) is used for guiding and external crushing. The inner drill bit (31) crushes the concrete in the center of the pile head (5) under the action of the rotary shear force to form a hollow cylindrical outer wall (55).

[0023] like Figure 4As shown, the hydraulic shears (4) are provided with shear teeth (41) with adjustable shearing angles to adapt to cast-in-place pile heads (5) of different sizes and shapes, thereby improving the concrete breaking effect of the cylindrical outer wall (55) and ensuring that the concrete is completely broken.

[0024] Further, if Figure 5 As shown in the figure, the operation process of rapid mechanical removal of the cast-in-place pile head is as follows: S101 Use a grinder to smooth the pile head, find the main reinforcement of the pile head and mark its position, and determine the center positioning point based on the main reinforcement.

[0025] S102 uses a small drilling rig to drill a positioning hole at the central positioning point to assist in the positioning of the pile breaker drill bit.

[0026] S103 uses the high-speed rotation of the pile breaker to press down, and the drill bit breaks the concrete to form a hollow cylindrical concrete outer wall.

[0027] S104 uses hydraulic shears to crush the outer wall concrete wrapped around the main reinforcement of the pile head and peel off the main reinforcement.

[0028] S105 cleans the debris and residual concrete around the pile head and completes the removal of the pile head. DETAILED DESCRIPTION

[0029] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further described below with reference to specific diagrams.

[0030] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present invention, so they have no substantial technical significance. Any modification of the structure, change of the proportion relationship or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the effects and purposes that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description, and are not used to limit the scope of the implementation of the present invention. The change or adjustment of their relative relationship should also be regarded as the scope of the implementation of the present invention without substantially changing the technical content.

[0031] The present invention is described in more detail below with reference to the accompanying drawings and embodiments. Example

[0032] 1. Project Overview The diameter of the cast-in-place pile in a bridge project is 1200mm, the strength is C40, the main reinforcement diameter is 32mm, and the average pile head needs to be broken at a height of 1m. Traditional manual breaking is inefficient and easy to damage the main reinforcement. The mechanical collaborative breaking device and method of the present invention are used to achieve efficient, accurate and non-destructive breaking.

[0033] 2. Implementation equipment and parameters 1. Grinding machine (1) The flat plate (11) has a diameter of 1000 mm, with 48 wear-resistant high-strength alloy pick teeth (12) embedded at the bottom, a rotation speed of 200 r / min, and a downward pressure of 8 kN. The grinder (1) grinds the concrete on the pile head surface until the main reinforcement (51) is exposed, and marks the center cross line (52).

[0034] 2. Small drilling rig (2) The diameter of the hole is 150 mm, the depth is 1.2 m (20 cm is reserved for anti-deviation verification), and the drill bit is an alloy pick spiral drill. The small drilling machine (2) drills a positioning hole (54) at the center of the pile head (53) to guide the pile breaker (3).

[0035] 3. Pile Breaker (3) The outer drill bit (32) has a diameter of 1100 mm (matching the pile diameter), the inner drill bit (31) has a diameter of 800 mm, the dual drill bits have a synchronous speed of 150 r / min, and the hydraulic drive pressure is 15 MPa. The observation hole (321) has a size of 200 mm×50 mm and is used to monitor the crushing progress in real time. The outer drill bit (32) straightens and guides and crushes the outer concrete, while the inner drill bit (31) spins and crushes the center concrete to form a cylindrical outer wall (55) with a wall thickness of 150 mm.

[0036] 4. Hydraulic shears (4) The opening range of the scissor teeth (41) is 300-1200 mm, the shear force is 500 kN, and the shear angle is adjustable (0°~30°). The scissor teeth (41) shear the residual concrete on the cylindrical outer wall (55) to protect the main reinforcement (51).

[0037] 3. Implementation steps Step 1: Use a grinder to smooth the pile head and mark the center Start the grinder (1), rotate and press down along the surface of the pile head (5), and the pick (12) grinds the concrete layer. Continue grinding until the main reinforcement (51) is completely exposed to form a flat working surface. Determine the center of the pile head (53) through the cross point (52) of the main reinforcement (51), and mark the pile head with a line ( Figure 1 ).

[0038] Step 2: Drill the positioning holes with a small drill Align the small drill (2) with the center (53) and drill vertically to a depth of 1.2m to form a positioning hole (54) with a diameter of 150mm. The drilling process is calibrated in real time to ensure that the verticality deviation of the hole is ≤2% ( Figure 2 ).

[0039] Step 3: The pile breaker crushes the concrete to form a cylindrical outer wall The outer drill bit (32) of the pile breaker (3) is lowered along the positioning hole (54) to the bottom of the pile, and the two drill bits are started to rotate synchronously. The pick (33) of the outer drill bit (32) breaks the concrete around the pile to a depth of 1m, and the inner drill bit (31) spins the central concrete at high speed to form a hollow cylindrical outer wall (55) ( Figure 3 ). The crushing progress is monitored through the observation hole (321) to ensure that the cylinder wall thickness is uniform.

[0040] Step 4: Hydraulic shears shear the remaining concrete Adjust the opening of the hydraulic shear (41) to 1200mm, adjust the angle of the shear teeth to 15°, and perform shearing and compression along the cylindrical outer wall (55) in a circular direction. Perform 4 symmetrical shearing and compression operations to completely crush the concrete until the main reinforcement (51) is completely peeled off ( Figure 4 ).

[0041] Step 5: Cleaning and acceptance A high-pressure air gun is used to remove the debris from the pile head, and the main reinforcement (51) is checked to be intact, and the thickness of the residual concrete on the cylindrical outer wall (55) is ≤10 mm. The total time required to break the pile head of a single pile is 1 hour (traditional manual labor requires 4 hours), and the mechanical breaking efficiency is four times that of manual operation.

[0042] 4. Technical Effect 1. Accuracy: The center positioning hole (54) guides the pile to a displacement of less than 10 mm, and the main reinforcement protection rate is 100%.

[0043] 2. High efficiency: Multiple machines work together to reduce the time required to break a 1m pile head by 75% compared to manual work.

[0044] 3. Economical: The service life of the replaceable picks (12) and (33) is up to 200 hours, and the cost per pile is reduced by 40%.

[0045] V. Description of the drawings (in conjunction with Figures 1 to 5 ) Figure 1 : After the pile head is ground flat by a grinder, the main reinforcement (51) is exposed and the cross line (52) marks the center (53).

[0046] Figure 2 : The positioning hole (54) vertically passes through the pile head, with a hole diameter of 150 mm.

[0047] Figure 3After the pile breaker is operated, a hollow cylindrical outer wall (55) with an inner diameter of 800 mm and an outer diameter of 1100 mm is formed at the center of the pile head.

[0048] Figure 4 : After the hydraulic shear (4) is used for shearing, the cylindrical outer wall (55) is broken, but the main reinforcement (51) is not damaged.

[0049] Figure 5 : The implementation flow chart clearly defines the connection between each process, and the total time for a single pile operation is 1 hour.

[0050] VI. Applicability Extension This case can be extended to bored piles with a pile diameter of 800-2500mm and a breaking height of 0.5-1.5m, and can be adapted to different engineering requirements by adjusting the drill bit size and hydraulic shear angle.

[0051] The present invention realizes high efficiency and precision in breaking pile heads through the coordinated operation of a grinder, a small drilling rig, a pile breaker and a hydraulic shear. The internal and external double drill bit structure of the pile breaker ensures the crushing of the concrete outside the pile head and the rapid cleaning of the central concrete. The hydraulic shear can adjust the angle according to the different sizes of the pile heads to ensure that each pile head can be broken efficiently. Compared with traditional manual or single mechanical operation methods, the operation time is shortened by 75%, and the breaking process is precise and not easy to damage the main reinforcement of the pile head, meeting the high standard requirements of modern construction for rapid processing of pile heads.

[0052] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. The present invention may be subject to various changes and improvements without departing from the spirit and scope of the present invention. These changes and improvements fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A device and method for quickly mechanically breaking the top of a bored pile, characterized in that: The device adopts a multi-machine collaborative operation system, including four core parts: grinder, small drill, pile breaker and hydraulic shear. The grinder is used to grind the pile head and mark the position of the main reinforcement of the pile head; the small drill is used to drill a hole in the center of the pile head to assist the pile breaker in positioning; the pile breaker is equipped with a double drill bit inside and outside the rotary pile breaker to crush and hollow out the concrete in the center of the pile head; the hydraulic shear is used to shear and crush the concrete wrapped around the main reinforcement of the pile head.

2. A device and method for rapid mechanical removal of a cast-in-place pile head according to claim 1, characterized in that: The bottom end of the grinder is a flat surface with picks embedded in the bottom. The grinder can be rotated to press down and peel the pile head concrete until the main reinforcement is exposed, and the center position of the pile head is elastically marked by the cross of the main reinforcement.

3. A device and method for rapid mechanical removal of a cast-in-place pile head according to claim 1, characterized in that: The small drilling rig drills a positioning hole in the center of the pile head to ensure that the pile breaker does not deviate when hollowing out the concrete in the center of the pile head, and the operation accuracy is improved through hole guidance.

4. A device and method for rapid mechanical removal of a cast-in-place pile head according to claim 1, characterized in that: The pile breaker is provided with inner and outer double drill bits for rotary pile breaking, with picks arranged at the bottom ends of the drill bits. The outer drill bit is used for guiding and external crushing, while the inner drill bit crushes concrete under the action of rotary shear force to form a hollow cylindrical outer wall.

5. A device and method for rapid mechanical removal of a cast-in-place pile head according to claim 1, characterized in that: The hydraulic shears are provided with shear teeth with adjustable shearing angles to adapt to cast-in-place pile heads of different sizes and shapes, thereby improving the concrete breaking effect of the cylindrical outer wall.

6. A device and method for rapid mechanical removal of cast-in-place pile heads according to claim 1, characterized in that: The cutting teeth at the bottom of the mechanical drill bits of grinders and pile breakers are made of wear-resistant high-strength alloy materials, and the service life and crushing efficiency are improved through the replaceable design.

7. A device and method for rapid mechanical removal of a cast-in-place pile head according to claims 1 to 6, characterized in that: The following steps are involved: ① Use a grinder to smooth the pile head, find the main reinforcement of the pile head and mark its position, and determine the center positioning point based on the main reinforcement; ② Use a small drill to drill a positioning hole at the center positioning point to assist the positioning of the pile breaker drill bit; ③ Use the high-speed rotation and downward pressure of the pile breaker to break the concrete and form a hollow cylindrical concrete outer wall; ④ Use hydraulic shears to shear and crush the outer wall concrete wrapped around the main reinforcement of the pile head and peel off the main reinforcement; ⑤ Clean the debris and residual concrete around the pile head to complete the removal of the pile head.

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