A design method for grooved prefabricated components

Abstract

The invention discloses a design method for a groove type prefabricated component, comprising the following steps: S1: designing a movable bottom mold platform; S2: designing a side mold, the side mold comprising two groove inner molds and two component outer molds, the groove inner mold comprising a groove panel and a groove supporting back rib fixed on the groove panel; the component outer mold comprising a component panel and a component supporting back rib fixed on the component panel; an opening is provided between the two groove inner molds; S3: installing the component outer mold, symmetrically fixing the two component outer molds on both sides of the bottom mold platform, and setting diagonal braces to temporarily fix the component outer molds, so that the component outer molds remain stable during the casting process; S4: installing the groove inner mold, symmetrically fixing the two groove inner molds at the center of the two component outer molds; S5: installing the tension screws and performing initial tightening; S6: installing the inner support at the groove, installing the inner support to maintain the verticality and shape of the inner mold of the groove.

Description

Technical Field

[0001] The invention belongs to the technical field of high-pile wharf engineering, and in particular relates to a design method for a groove-type prefabricated component. Background Art

[0002] In modern port construction, high-pile docks, as an important hydraulic structure, not only provide a place for ships to berth and load and unload, but also carry the functions of many supporting facilities such as power supply and lighting, water supply and drainage, and environmental protection. These facilities usually need to be laid and installed through integrated pipelines, and grooved prefabricated components are widely used because they can effectively accommodate and protect these pipelines. However, traditional construction methods face many challenges when dealing with such irregular geometries.

[0003] When the traditional closed formwork design is applied to groove-type prefabricated components, due to its closed structure, the bottom plate of the beam cannot be effectively vibrated during the pouring of concrete. This problem directly leads to two major technical difficulties: first, the concrete cannot be fully compacted, and a large number of bubbles are easily generated. These bubbles will form pores after the formwork is removed, affecting the strength and durability of the prefabricated components; second, the presence of bubbles makes the surface quality of the inner wall of the groove poor, reducing the aesthetics and increasing the workload of later repairs and maintenance. In addition, the design of traditional formwork is also difficult to adapt to the characteristics of small construction sites, a wide variety of prefabricated components and tight construction schedules. Conventional concrete pedestals need to be frequently dismantled and rebuilt during use, which not only consumes a lot of time and labor, but also significantly increases construction costs. At the same time, this fixed construction method lacks flexibility and cannot dynamically adjust the production quantity according to the progress of the project, thus limiting the improvement of construction efficiency.

[0004] In order to deal with the above problems, there are also some improvement measures in the prior art, such as using segmented formwork or adding additional vibration equipment. However, these methods often only partially solve the problem and do not fundamentally overcome the defects of traditional formwork design. Although the segmented formwork can improve the density of concrete to a certain extent, due to the poor sealing and stability of the joints, leakage is prone to occur, affecting the final quality. The additional vibration equipment increases the complexity and cost of construction, and may also cause over-vibration of the concrete due to improper operation, causing structural damage. Therefore, a new formwork design is urgently needed to completely solve these problems in order to meet the needs of high-quality and efficient construction in the construction of high-pile wharfs. Summary of the invention

[0005] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to provide a design method for grooved prefabricated components, which solves the problems existing in the prior art by improving the density of the bottom plate and adopting technical means such as a movable bottom mold platform.

[0006] To solve the above problems, the technical solution adopted by the present invention is as follows: A design method of a grooved prefabricated component comprises the following steps:

[0007] S1: Design a movable bottom formwork platform, lay two layers of square timber on the prefabrication site, fix the square timber with iron nails, and fix the wooden formwork on the square timber;

[0008] S2: Design a side template, the side template comprising two groove inner templates and two component outer templates, the groove inner template comprising a groove panel and a groove supporting back rib fixed on the groove panel; the component outer template comprising a component panel and a component supporting back rib fixed on the component panel; an opening is provided between the two groove inner templates;

[0009] S3: Install the outer formwork of the component, symmetrically fix the two outer formworks of the component on both sides of the bottom formwork platform, and set diagonal braces to temporarily fix the outer formworks of the component, so that the outer formworks of the component remain stable during the pouring process;

[0010] S4: installing the inner templates of the groove, and symmetrically fixing the two inner templates of the groove at the center of the outer templates of the two components;

[0011] S5: Install the tension screws and perform initial tightening. The tension screws pass through the gaps between the square timbers and the gaps between the back ribs at the top of the side formwork, and first nuts are installed at both ends of the tension screws respectively;

[0012] S6: Install the inner support at the groove. At the bottom of the groove, install the inner support to maintain the verticality and shape of the template inside the groove.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention allows the vibrating rod to be directly inserted into the bottom of the groove for vibration by designing a movable sub-bottom mold and an open side mold, thereby ensuring that the concrete is fully compacted, effectively eliminating bubbles, and avoiding quality problems caused by the closed mouth that cannot be vibrated. This improvement not only enhances the strength and durability of the base plate, but also greatly improves the surface quality of the inner wall of the groove, reduces the workload of later repairs and maintenance, and improves the quality level of the overall project. At the same time, the use of a movable bottom mold platform can flexibly adjust the production quantity of prefabricated components according to the progress of on-site operations, avoiding the trouble of frequent dismantling and reconstruction of conventional concrete pedestals. This method not only speeds up the construction progress, but also shortens the overall construction time.

[0014] In the above-mentioned design method, the two layers of square timbers in step S1 include a plurality of transverse square timbers and a plurality of longitudinal square timbers, the transverse square timbers are located on the upper layer of the longitudinal square timbers, and the transverse square timbers and the longitudinal square timbers are perpendicular to each other.

[0015] In the above-mentioned design method, the groove supporting back rib in step S2 includes a first groove supporting back rib, a second groove supporting back rib and a third groove supporting back rib, the first groove supporting back rib is fixed on the groove panel, the second groove supporting back rib is fixed on one side of the groove panel, and the third groove supporting back rib is fixed on the top of one side of the second groove supporting back rib.

[0016] In the above-mentioned design method, the component supporting back ribs in step S2 include a first component supporting back ribs, a second component supporting back ribs and two third component supporting back ribs, wherein the first component supporting back ribs is fixed on the component panel, the second component supporting back ribs is fixed on one side of the component panel, and the two third component supporting back ribs are respectively fixed on both side ends of the second component supporting back ribs.

[0017] In the above-mentioned design method, the opening in step S2 enables the vibrating rod to penetrate into the bottom of the groove for vibration, so as to make the concrete dense and expel bubbles.

[0018] In the above-mentioned design method, the prefabricated component needs to be adjusted after step S7. After the installation accuracy of the prefabricated component reaches the design standard, the tension screws are finally tightened, and second nuts are added to both ends of the tension screws and tightened.

[0019] In the above-mentioned design method, the movable bottom formwork platform in step S1 can adjust the size and position according to the needs of the construction site.

[0020] According to the above-mentioned design method, the connection between the tension screws and the first nut and the second nut can maintain the inner formwork of the groove and the outer formwork of the component stable, so that the inner formwork of the groove and the outer formwork of the component will not deform during the pouring process. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A schematic diagram of the steps of the design method according to an embodiment of the present invention;

[0022] Figure 2 It is a structural schematic diagram of a bottom mold platform according to an embodiment of the present invention;

[0023] Figure 3 This is a schematic diagram of the inner template structure of a groove according to an embodiment of the present invention;

[0024] Figure 4 A schematic diagram of the outer template structure of a component according to an embodiment of the present invention;

[0025] Figure 5 This is a schematic diagram of the outer template installation structure of a component according to an embodiment of the present invention;

[0026] Figure 6It is a schematic diagram of the installation structure of the groove inner template and the component outer template according to an embodiment of the present invention;

[0027] Explanation of the accompanying figures: 1000 bottom formwork platform, 1100 two-layer square timber, 1110 horizontal square timber, 1120 longitudinal square timber, 1130 wooden formwork, 2000 side formwork, 2100 groove inner formwork, 2110 groove panel, 2120 groove supporting back rib, 2121 first groove supporting back rib, 2122 second groove supporting back rib, 2123 third groove supporting back rib, 2200 component outer formwork, 2210 component panel, 2220 component supporting back rib, 2221 first component supporting back rib, 2222 second component supporting back rib, 2223 third component supporting back rib, 3000 bottom square timber, 4000 opening, 5000 tension screws. DETAILED DESCRIPTION

[0028] The embodiments of the present invention are described in detail below. Figures 1 to 6The embodiment of the present invention provides a design method for a groove type prefabricated component, comprising the following steps: S1: designing a movable bottom mold platform 1000, laying two layers of square wood 1100 on the prefabrication site, fixing the square wood with iron nails, and fixing a wooden template 1130 on the square wood; S2: designing a side template 2000, the side template 2000 includes two groove inner templates 2100 and two component outer templates 2200, the groove inner template 2100 includes a groove panel 2110 and a groove supporting back rib 2120 fixed on the groove panel 2110; the component outer template 2200 includes a component panel 2210 and a component supporting back rib 2220 fixed on the component panel 2210; an opening 4000 is provided between the two groove inner templates 2100; S3: Install the component outer formwork 2200, fix the two component outer formworks 2200 symmetrically on both sides of the bottom formwork platform 1000, and set diagonal braces to temporarily fix the component outer formworks 2200 to keep the component outer formworks 2200 stable during the pouring process; S4: Install the groove inner formwork 2100, and fix the two groove inner formworks 2100 symmetrically in the center of the two component outer formworks 2200; S5: Install the tension screws 5000 and tighten them initially. The tension screws 5000 pass through the gaps between the square timbers and the gaps between the top back ribs of the side formworks 2000, and install the first nuts at both ends of the tension screws 5000 respectively; S6: Install the inner support at the groove. At the bottom of the groove, install the inner support to maintain the verticality and shape of the inner formwork 2100 of the groove. The present invention allows the vibrating rod to be directly inserted into the bottom of the groove for vibration by designing a movable sub-bottom mold 1000 and an open side mold 2000, thereby ensuring that the concrete is fully compacted, effectively eliminating bubbles, and avoiding quality problems caused by the closed mouth that cannot be vibrated. This improvement not only enhances the strength and durability of the base plate, but also greatly improves the surface quality of the inner wall of the groove, reduces the workload of later repairs and maintenance, and improves the quality level of the overall project. At the same time, the use of a movable bottom mold platform 1000 can flexibly adjust the production quantity of prefabricated components according to the progress of on-site operations, avoiding the trouble of frequent dismantling and reconstruction of conventional concrete pedestals. This method not only speeds up the construction progress, but also shortens the overall construction time.

[0029] Furthermore, the design method proposed in this application refers to Figure 1 , through multiple steps to ensure the stability of the prefabricated frame and the quality of concrete pouring, step S1 provides a flexible support foundation for the entire construction process, of course, the present invention does not limit the specific size and position of the bottom mold platform 1000, preferably, the two layers of square timber 1100 in step S1 include a plurality of transverse square timber 1110 and a plurality of longitudinal square timber 1120, the transverse square timber 1110 is located on the upper layer of the longitudinal square timber 1120, and the transverse square timber 1110 and the longitudinal square timber 1120 are perpendicular to each other. Figure 1, through the stacking arrangement of two layers of square timbers 1100 (horizontal square timbers 1110 and longitudinal square timbers 1120), a stable support structure is formed. This stacking arrangement not only enhances the overall rigidity of the bottom mold platform 1000, but also makes the bottom mold platform 1000 have good anti-deformation ability, which is suitable for various complex construction environments. The horizontal square timbers 1110 are located on the upper layer of the longitudinal square timbers 1120, and the longitudinal square timbers 1120 are located on the prefabrication site. The two are arranged perpendicularly and crosswise to form a criss-cross support system, which effectively disperses the load and reduces local stress concentration, thereby improving the bearing capacity and stability of the bottom mold platform 1000. Furthermore, the movable bottom mold platform 1000 in step S1 can adjust the size and position according to the needs of the construction site, and can adjust the position at will according to the needs of the construction site, thereby improving the construction efficiency and the utilization rate of the site.

[0030] Reference Figure 6 The side formwork 2000 mentioned in step S2 includes a combination of a groove inner formwork 2100 and a component outer formwork 2200, wherein there are two groove inner formworks 2100 and two component outer formworks 2200, and the two groove inner formworks 2100 are symmetrically installed inside the component outer formwork 2200. After the two groove inner formworks 2100 are installed, an opening 4000 is provided in the center thereof. Of course, the present invention does not limit the specific size of the opening 4000. Preferably, the opening 4000 in step S2 can enable the vibrating rod to penetrate into the bottom of the groove for vibration, so as to make the concrete dense and discharge bubbles, thereby avoiding the air hole problem caused by the traditional closed formwork and improving the quality and aesthetics of the prefabricated component. Figure 5 In step S3, when installing the component outer formwork 2200, the two component outer formworks 2200 are symmetrically installed on the bottom formwork platform 1000, and at the same time, diagonal braces are set on the component outer formworks 2200 to ensure the stability of the formwork during the pouring process, prevent the formwork from shifting or deforming, and ensure the safety of the structure. In step S4, when installing the groove inner formwork 2100, the two groove inner formworks 2100 are symmetrically installed in the component outer formwork 2200 that has been installed in step S3, ensuring the centering and uniform force of the formwork. The overall stability of the formwork system is further enhanced. Of course, the present invention does not limit the specific structure of the groove inner formwork 2100 and the component outer formwork 2200. Preferably, refer to Figure 3,, the groove supporting back rib 2120 in step S2 includes a first groove supporting back rib 2121, a second groove supporting back rib 2122 and a third groove supporting back rib 2123, the first groove supporting back rib 2121 is fixed on the groove panel 2110, the second groove supporting back rib 2122 is fixed on one side of the groove panel 2110, and the third groove supporting back rib 2123 is fixed on the top of one side of the second groove supporting back rib 2122; through the combination of multiple channel steel back ribs, the stability of the groove inner side template 2100 is significantly enhanced. The first groove support back rib 2121 is directly fixed on the groove panel 2110, providing the main support function and ensuring the flatness and strength of the panel. The second groove support back rib 2122 is fixed on one side of the groove panel 2110, further strengthening the lateral support of the template and preventing the template from lateral deformation during the pouring process. The third groove support back rib 2123 is fixed on the top of the second groove support back rib 2122, effectively resisting vertical and lateral loads and ensuring the overall rigidity of the template. This multi-level and multi-directional support design not only improves the anti-deformation ability of the template, but also makes the template more stable during the pouring process, avoiding concrete quality problems caused by template deformation.

[0031] Furthermore, refer to Figure 4 , the component support back rib 2220 in step S2 includes a first component support back rib 2221, a second component support back rib 2222 and two third component support back ribs 2223, the first component support back rib 2221 is fixed on the component panel 2210, the second component support back rib 2222 is fixed on one side of the component panel 2210, and the two third component support back ribs 2223 are respectively fixed on the two side ends of the second component support back rib 2222. The first component support back rib 2221 is directly fixed on the component panel 2210, providing the main support function and ensuring the flatness and strength of the panel. The second component support back rib 2222 is fixed on one side of the component panel 2210, further strengthening the lateral support of the template and preventing the template from lateral deformation during the pouring process. The two third component support back ribs 2223 are respectively fixed on the two side ends of the second component support back rib 2222, forming a stable frame structure, effectively resisting vertical and lateral loads, and ensuring the overall rigidity of the template. This multi-level, multi-directional support design not only improves the formwork's ability to resist deformation, but also makes the formwork more stable during the pouring process, avoiding concrete quality problems caused by formwork deformation.

[0032] Furthermore, refer to Figure 6After installing the outer template 2200 of the component and the inner template 2100 of the groove, the template is fixed with the tension screw 5000. First, the tension screw 5000 is initially tightened. The tension screw 5000 passes through the gaps between the horizontal square woods 1110 of the bottom template platform 1000 and the gaps between the channel steels at the top of the side template 2000. The nuts are installed at both ends of the tension screw 5000 and the top of the groove to initially tighten the prefabricated component. Before pouring concrete, the initial tightening of the tension screw 5000 can initially fix the inner template 2100 of the groove and the outer template 2200 of the component together to form a stable frame structure. This step prevents the template from being significantly displaced or deformed during the subsequent adjustment and pouring process, ensuring the overall stability of the template system. By initially tightening the tension screw 5000, a certain pre-tightening force can be applied between the templates, so that the template panel and the back rib are closely fitted, the gap between the templates is reduced, and the occurrence of concrete leakage during the pouring process is prevented. After the initial tightening, the tension screws 5000 still have a certain adjustment margin, and the construction personnel can make fine adjustments to the formwork system as needed to ensure that the installation accuracy of the formwork meets the design requirements. This adjustability allows construction personnel to make final corrections to the position, verticality, horizontality, etc. of the formwork before pouring to ensure the quality of prefabricated components.

[0033] Further, after the initial tightening of the tension screw 5000 is completed, the inner support at the groove is installed to ensure the verticality and shape accuracy of the inner template 2100 of the groove. Of course, the present invention does not limit the specific material of the inner support. Preferably, the inner support is made of the bottom square wood 3000 to avoid the problem of shape deviation after pouring. Further, after step S7, the prefabricated component needs to be adjusted. After the installation accuracy of the prefabricated component reaches the design standard, the tension screw 5000 is finally tightened, and the second nut is added and tightened at both ends of the tension screw 5000. After the pouring is completed, the prefabricated component is finely adjusted to ensure that its installation accuracy reaches the design standard. This is a key step to ensure the quality of the prefabricated component. By finally tightening the tension screw 5000 and adding and tightening the second nut at both ends, the overall rigidity of the template system is further enhanced, ensuring that the template does not deform during the pouring process. This design not only improves the stability of the template system, but also effectively prevents the template from shifting or deforming during the pouring process, ensuring that the shape and size of the prefabricated component meet the design requirements. In addition, the final tightening operation can also enhance the sealing of the formwork system, prevent leakage, and further improve the construction quality.

[0034] It should be noted that in the description of the present invention, if there are any orientation descriptions, such as up, down, front, back, left, right, etc., the orientations or positional relationships indicated are all based on the orientations or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed or operated in a specific orientation, and cannot be understood as a limitation on the present invention.

[0035] In the description of the present invention, the meaning of "several" is one or more, the meaning of "more" is two or more, "greater than", "less than", "exceed" etc. are understood as not including the number, and "above", "below", "within" etc. are understood as including the number. If there is a description of the design method of the first grooved prefabricated component or the second, it is only used for the purpose of distinguishing the technical features, and cannot be understood as indicating or implying the relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0036] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, connecting, etc. should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention in combination with the specific content of the technical solution.

[0037] The above-mentioned embodiments are only preferred embodiments of the present invention and cannot be used to limit the scope of protection of the present invention. Any non-substantial changes and substitutions made by technicians in this field on the basis of the present invention shall fall within the scope of protection required by the present invention.

Claims

1. A design method for a grooved prefabricated component, characterized in that: The following steps are involved: S1: Design a movable bottom formwork platform (1000), lay two layers of square timber (1100) on the prefabrication site, fix the square timber with iron nails, and fix the wooden formwork (1130) on the square timber; S2: Designing a side formwork (2000), wherein the side formwork (2000) comprises two groove inner side formworks (2100) and two component outer side formworks (2200), wherein the groove inner side formwork (2100) comprises a groove panel (2110) and a groove supporting back rib (2120) fixed on the groove panel (2110); the component outer side formwork (2200) comprises a component panel (2210) and a component supporting back rib (2220) fixed on the component panel (2210); an opening (4000) is provided between the two groove inner side formworks (2100); S3: installing the component outer formwork (2200), symmetrically fixing the two component outer formworks (2200) on both sides of the bottom formwork platform (1000), and setting diagonal braces to temporarily fix the component outer formworks (2200) so that the component outer formworks (2200) remain stable during the pouring process; S4: installing the groove inner template (2100), and symmetrically fixing the two groove inner templates (2100) at the center of the two component outer templates (2200); S5: Install the tension screws (5000) and perform initial tightening, wherein the tension screws (5000) pass through the gaps between the square timbers and the gaps between the top back ribs of the side formwork (2000), and first nuts are installed at both ends of the tension screws (5000); S6: Install an inner support at the groove. At the bottom of the groove, install an inner support to maintain the verticality and shape of the inner template (2100) of the groove.

2. The design method according to claim 1, characterized in that: The two layers of square timbers (1100) in step S1 include a plurality of transverse square timbers (1110) and a plurality of longitudinal square timbers (1120), wherein the transverse square timbers (1110) are located on an upper layer of the longitudinal square timbers (1120), and the transverse square timbers (1110) and the longitudinal square timbers (1120) are perpendicular to each other.

3. The design method according to claim 2, characterized in that: The groove supporting back rib (2120) in step S2 includes a first groove supporting back rib (2121), a second groove supporting back rib (2122) and a third groove supporting back rib (2123), wherein the first groove supporting back rib (2121) is fixed on the groove panel (2110), the second groove supporting back rib (2122) is fixed on one side of the groove panel (2110), and the third groove supporting back rib (2123) is fixed on the top of one side of the second groove supporting back rib (2122).

4. The design method according to claim 2, characterized in that: The component supporting back ribs (2220) in step S2 include a first component supporting back ribs (2221), a second component supporting back ribs (2222) and two third component supporting back ribs (2223), wherein the first component supporting back ribs (2221) is fixed on the component panel (2210), the second component supporting back ribs (2222) is fixed on one side of the component panel (2210), and the two third component supporting back ribs (2223) are respectively fixed on the two side ends of the second component supporting back ribs (2222).

5. The design method according to claim 1, characterized in that: The opening (4000) in step S2 enables the vibrating rod to penetrate into the bottom of the groove for vibration, so as to make the concrete dense and expel air bubbles.

6. The design method according to claim 1, characterized in that: After step S7, the prefabricated components need to be adjusted. After the installation accuracy of the prefabricated components reaches the design standard, the tension screws (5000) are finally tightened, and second nuts are added to both ends of the tension screws (5000) and tightened.

7. The design method according to claim 1, characterized in that: The movable bottom formwork platform (1000) in step S1 can adjust the size and position according to the needs of the construction site.

8. The design method according to claim 1, characterized in that: In the step S6, the inner support is made of bottom square wood (3000).

9. The design method according to claim 6, characterized in that: The connection between the tension screw (5000) and the first nut and the second nut can maintain the inner formwork (2100) of the groove and the outer formwork (2200) of the component stable, so that the inner formwork (2100) of the groove and the outer formwork (2200) of the component do not deform during the pouring process.

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