Pouring method of novel secondary lining layered pouring trolley

Abstract

The invention relates to the technical field of tunnel reinforcement, in particular to a pouring method of a novel secondary lining layered pouring trolley, and provides corresponding technical measures for controlling quality through practical improvement on traditional equipment with mold grouting and adoption of a steel end mold and longitudinal waterstop positioning clamp combination module system. The trolley top formwork of the secondary lining formwork trolley is used as a formwork during grouting, and the liquid level relay is adopted to detect the compaction condition of the tunnel vault concrete in real time, so that the grouting operation time is saved, and the construction quality of a secondary lining structure is improved.

Description

Technical Field

[0001] The invention relates to the technical field of tunnel reinforcement, in particular to a casting method of a novel secondary lining layered casting trolley. Background Art

[0002] Composite lining structures are widely used in tunnel construction. They are generally composed of primary support and secondary lining. That is, after the excavation of the tunnel soil, anchor rods and shotcrete are promptly applied as primary support to control the deformation of the surrounding rock and bear the construction load. After the deformation of the surrounding rock is basically stable, the secondary lining is applied. The two initial layers are also called primary support and secondary lining, and the last layer of permanent lining structure is called tertiary lining.

[0003] During the pouring of concrete for the permanent lining structure, the voids and hollowing behind the arch are common quality problems for tunnels. During the design of the trolley, it is considered that when pouring the concrete for the secondary lining arch, the concrete pouring of the arch is not dense due to workers' observation errors and untimely pumping of materials, resulting in voids and hollowing.

[0004] Therefore, it is necessary to design a new casting method for the second lining layered casting trolley, use the trolley top formwork of the second lining formwork trolley as the template for grouting, and use the liquid level relay to perform real-time detection of the compaction of the tunnel vault concrete, which saves the grouting operation time and improves the construction quality of the second lining structure. Summary of the invention

[0005] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a new casting method of a second lining layered casting trolley, using the trolley top formwork of the second lining formwork trolley as the template during grouting, and using a liquid level relay to perform real-time detection of the compaction condition of the tunnel vault concrete, thereby saving grouting operation time and improving the construction quality of the second lining structure.

[0006] In order to achieve the above object, the present invention provides a new casting method of a secondary lining layered casting trolley:

[0007] The trolley includes a walking mechanism assembly, a gantry assembly, a template assembly, an electrical operation control system, a hydraulic system, an anti-emptying warning system, a vault with mold grouting system, a chute window-by-window mold entry system, and a steel end mold and longitudinal water stop belt positioning fixture combined module system;

[0008] The walking mechanism assembly includes two driving wheel trolleys and two passive wheel trolleys, which are respectively installed under two walking beams on both sides;

[0009] The gantry assembly consists of six gantry frames. The outer side of the column is equipped with a screw supporting the single-side wall formwork and 4 sets of cylinders for adjusting the side formwork. The upper part of the gantry is a working platform. The working platform is equipped with a template translation device for operating the hydraulic valve to make the template translate left and right as a whole. There are also four arch template lifting cylinders and a hydraulic control panel.

[0010] The template assembly consists of an arch template and two side templates on the circumference, which are connected by bolts to form a template of required length in the length direction. The side template is connected to the arch template by hinges, and the side template can rotate around the hinges to adjust the expansion and contraction of the template to meet the requirements of section lining;

[0011] The hydraulic system consists of a hydraulic control panel, four lifting cylinders, four sets of side template adjustment cylinders, four translation template cylinders and various valves and pipelines;

[0012] The method of the chute window-by-window feeding system is: by combining the main hopper, main chute, three-way diversion chute, diversion string tube and window chute, by operating the corresponding gate valve, the concrete flows to each working window, which is used for the window-by-window feeding and pouring of the secondary lining arch wall concrete;

[0013] The specific method of the vault mold grouting system includes the following steps:

[0014] S1, mounting flange with hole opening on the top plate of the trolley;

[0015] S2, install RPC grouting pipe and exhaust pipe to support the waterproof board;

[0016] S3, record the buried length of the RPC pipe on the recording board;

[0017] S4, pouring concrete and observing the slurry coming out of the embedded pipe;

[0018] S5, the end of the grouting pipe is connected to the grouting machine pipe;

[0019] S6, grouting liquid preparation and grouting with mold;

[0020] S7, observe the pressure gauge and the slurry discharge from the exhaust hole;

[0021] S8, if the vent hole discharges thick slurry, go to S9; if the vent hole does not discharge thick slurry, determine whether the pressure is less than 1.0Mpa, if the pressure is less than 1.0Mpa, go to S6, if the pressure is not less than 1.0Mpa, go to S5 and transfer to the spare grouting hole;

[0022] S9, grouting is completed, and the hose of the grouting machine is removed;

[0023] S10, remove the positioning flange after the slurry initially sets.

[0024] The hydraulic control panel includes a motor, an oil pump, a filter and an eight-way valve.

[0025] The spare slurry outlet in S8 is the middle exhaust hole on the top plate of the trolley.

[0026] The grouting material in the vault formwork grouting system adopts high-fluidity, slightly expanding, early-strength filling mortar.

[0027] The filling mortar is designed to meet the requirements of no water bleeding, slight expansion, early strength, high strength, excellent self-leveling performance and long construction time.

[0028] The steel end formwork and the longitudinal waterstop positioning fixture combined module system is: the waterstop installation is assisted by improving the waterstop positioning fixture, and the steel end formwork and the lining trolley arc-shaped template are welded and fixed firmly.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] The present invention uses a liquid level relay to detect the compactness of the tunnel vault concrete in real time, changing the traditional method of judging the compactness of the vault by opening a window and relying on the construction experience of workers, reducing the error rate of manual judgment, and detecting the hollowing phenomenon behind the second lining vault during the construction process, which can largely avoid and reduce the defects of the second lining construction vault such as hollowness and non-compactness. Thereby reducing the cost of repairing the defects such as hollowing and non-compactness behind the vault in the later stage, and greatly saving the tunnel construction period.

[0031] The present invention utilizes the trolley top formwork of the secondary lining formwork trolley as the formwork for grouting, and adopts a liquid level relay to perform real-time detection on the compactness of the tunnel vault concrete, thereby saving grouting operation time and improving the construction quality of the secondary lining structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a front view of the trolley according to an embodiment of the present invention.

[0033] Figure 2 It is a side view of the trolley according to an embodiment of the present invention.

[0034] Figure 3 1 is a top view of a trolley according to an embodiment of the present invention.

[0035] Figure 4 This is a physical display of the secondary lining concrete pouring trolley on site according to an embodiment of the present invention.

[0036] Figure 5 Schematic diagram of the flow distribution paths at each level of the mold in an embodiment of the present invention.

[0037] Figure 6 This is a schematic diagram of guiding the sliding grooves of each level of windows to each working window in an embodiment of the present invention.

[0038] Figure 7 This is a schematic diagram of the step-by-step window feeding by adjusting the pull-out baffle switch according to an embodiment of the present invention.

[0039] Figure 8 It is a schematic diagram of a novel anti-emptying warning system for a secondary lining layered casting trolley according to an embodiment of the present invention.

[0040] Fig. 9 This is a schematic diagram of the site of the novel secondary lining layered casting trolley arch crown grouting system according to an embodiment of the present invention.

[0041] Fig.10 This is a process flow chart of the mold grouting process according to an embodiment of the present invention.

[0042] Fig.11 It is a schematic diagram of the steel end mold and longitudinal waterstop positioning fixture module system according to an embodiment of the present invention.

[0043] Fig.12 This is a schematic diagram of the on-site appearance of the secondary lining concrete after the formwork is removed according to an embodiment of the present invention. DETAILED DESCRIPTION

[0044] See also Figures 1 to 12 The present invention is now further described in conjunction with the accompanying drawings. The present invention provides a new casting method for a second lining layered casting trolley:

[0045] The trolley includes a walking mechanism assembly, a gantry assembly, a template assembly, an electrical operation control system, a hydraulic system, an anti-empty warning system, a vault mold grouting system, a chute window-by-window mold entry system, and a steel end mold and longitudinal water stop belt positioning fixture combined module system, such as Figure 1 to Figure 3 shown.

[0046] Among them, the walking mechanism assembly is composed of four walking trolleys, two active wheel trolleys and two passive wheel trolleys, which are respectively installed under the two walking beams on both sides. The operator operates the power switch to move the trolley (forward or backward).

[0047] The gantry assembly consists of six gantry frames. On the outside of the column, there is a screw that supports the single-side wall template and 4 sets of cylinders that adjust the side templates. The upper part of the gantry is a working platform with a template translation device that can operate the hydraulic valve to make the template move left and right as a whole. There are also four arch template lifting cylinders and a hydraulic control panel.

[0048] The formwork assembly determines the integrity of the concrete surface. It consists of an arch formwork and two side formworks on the circumference. In the length direction, it is connected by bolts to form the required length of the formwork. The side formwork is connected to the arch formwork by hinges, and the side formwork can rotate around the hinges to adjust the expansion and contraction of the formwork to meet the requirements of the cross-section lining.

[0049] The hydraulic system consists of a hydraulic control panel (consisting of a motor, oil pump, filter, eight-way valve, etc.), four lifting cylinders, four sets of side template adjustment cylinders, four translation template cylinders, various valves and pipelines.

[0050] In order to improve the pouring quality of the secondary lining concrete, the new secondary lining layered pouring trolley is equipped with an anti-emptying warning system, a vault mold grouting system, a slide window-by-window mold entry system, and a steel end mold and longitudinal waterstop positioning fixture combined module system.

[0051] Safety warning standards are hung on the trolley operating platform, such as signs prohibiting open flames, wearing helmets, height restrictions, width restrictions, speed limits, etc. Contour lights are hung on each gantry to prevent vehicle collisions during construction in the tunnel. Customized ladders are used for up and down safety ladders to ensure safe and stable use, and reflective paint is applied to the ladder railings. Guardrails are uniformly installed on the outside of all construction platforms to prevent workers from falling due to improper operation. Distribution boxes are installed on both sides of the trolley's inner channel, and are arranged using the "three-level power distribution, two-level leakage protection, one machine and one gate, one leakage and one box" standard. Fire extinguisher boxes, emergency medicine boxes and monitoring and measurement data boxes are arranged in appropriate locations. The operating procedures and safety operating regulations of the second lining trolley are hung at appropriate locations on the two gantry. Reflective cones are arranged 10m in front of the delivery pump, with a spacing of 2m, to warn passing vehicles to pay attention to safety. On-site photos of the second lining concrete pouring formwork trolley are as follows Figure 4 shown.

[0052] Among them, the trolley is designed and produced with a window-by-window feeding system. Through the combination of the main hopper, main chute, "three-way" diversion trough, diversion string and window chute, the corresponding plug valve is simply operated to make the concrete flow to each working window, so as to realize the window-by-window feeding and pouring of the secondary lining arch wall concrete. Figure 5 As shown. Install the main hopper, main chute, "three-way" diversion chute, and diversion string on the top platform. Install the diversion chute of each level window to guide it to each working window as shown. Figure 6 By adjusting the switch of the baffle plate, the graded feeding can be realized window by window. Figure 7 shown.

[0053] The advantages of the window-by-window mold placing system are: it enables the lining side wall concrete to be placed in the mold layer by layer and window by window, effectively avoiding the disadvantages of concrete segregation, aggregate accumulation, and the formation of "human" slope cold joints; it improves the physical quality and appearance quality of the lining side wall concrete pouring; it reduces the side wall pouring pipe replacement process, reduces labor intensity, and saves pouring time; the chute system is economical and applicable, and can be installed once and reused; the on-site operation is simple and convenient, and it is easy for front-line workers to accept; the chute system adopts a humanized design, the working channel is unobstructed and orderly, and the safety is high.

[0054] The voids and hollowing behind the secondary lining arch are common quality problems in tunnels. During the trolley design process, it is considered that when pouring the secondary lining arch concrete, the arch concrete is not poured densely due to workers' observation errors and untimely pumping of materials, resulting in voids and hollowing.

[0055] Therefore, the present invention also includes an anti-air escape warning system, specifically:

[0056] The second lining trolley is equipped with an extrusion and compaction sensor. The principle is similar to that of the pressure sensor. The machine consists of a sensing belt and a sensor. The length of one section of the sensing belt is the same as the length of the first mold of the second lining. It is pre-buried in the center line waterproof board position of the tunnel top and is tightly attached. The contact surface of the sensing belt is connected to the second lining concrete. The sensor works by connecting with the sensing belt. Due to the pressure generated when the concrete is poured, the position of the sensing belt is just tightly attached to the waterproof board. When the concrete is poured to the position of the arch waterproof board, it will produce an extrusion force on the sensing belt. When the effect is taken, it means that the concrete pouring has reached the arch waterproof board position, and the lining thickness here is qualified, and the sensor works and shows a green light. When the sensing light is red, it means that the sensing belt here is not subjected to extrusion pressure, the lining thickness is unqualified, and it must be dealt with in time.

[0057] The sensors are 21 induction lights. The length of the second lining and one mold is 10m. Each gap of the induction lights represents 0.5m. The corresponding parts are processed in time according to the working status of the induction lights. The photo of the new second lining layered casting trolley anti-emptying warning system is as follows Figure 8 shown.

[0058] During the construction of the secondary lining, a liquid level relay is used to detect the density of the tunnel vault concrete in real time, changing the traditional method of judging the density of the vault by opening windows and relying on the construction experience of workers, reducing the error rate of manual judgment, and detecting the hollowing phenomenon behind the secondary lining vault during the construction process, which can largely avoid and reduce the defects of the vault such as hollowness and non-density in the secondary lining construction. This can reduce the cost of repairing the defects such as hollowing and non-density behind the vault in the later stage, and can greatly save the tunnel construction period.

[0059] Furthermore, the grouting holes with molds have been designed when the trolley is produced. The present invention can timely solve the problem of voids caused by the loose pouring of the vault concrete during the pouring process. The construction procedure is: waterproof board construction → installation of RPC grouting pipe → lining concrete construction → backfill grouting → mold removal → grouting effect inspection → end. The on-site photos of the vault grouting system with molds are as follows: Fig. 9 shown.

[0060] The process flow chart of mold grouting is as follows: Fig.10 shown.

[0061] The grouting material uses high-fluidity, micro-expansion, early-strength filling mortar, referred to as filling mortar, which has no water seepage, micro-expansion, early strength, high strength, excellent self-leveling performance, and a long construction time. Its performance reaches or even exceeds the indicators of lining concrete, has a certain waterproof effect, and hydration heat release is uniform, which is very beneficial to the repair and reinforcement of lining concrete. The specific parameters are shown in Table 1 below.

[0062] Table 1 Grouting material performance parameters

[0063]

[0064] During the construction of the traditional tunnel secondary lining end formwork, a combination of steel bar positioning cards and wooden formwork is used to fix the position of the waterstop. Since the Xiangdong Tunnel in this embodiment uses a steel plate rubber waterstop, which is heavy and difficult to bend and difficult to center, after the wooden formwork is used to close the lining end and cast, the concrete surface of the construction joint is uneven and has poor appearance quality.

[0065] In order to solve the problem of difficulty in positioning the circumferential and longitudinal construction joints of the tunnel, the installation of the waterstop is assisted by improving the waterstop positioning fixture. The steel end formwork is firmly welded and fixed to the arc-shaped formwork of the lining trolley. Compared with the traditional wooden formwork closed end, it saves the time of closing the end wooden formwork, thereby saving labor costs and improving construction efficiency. The second lining construction of Xiangdong Tunnel adopts a steel end formwork + waterstop positioning fixture combined module system. After pouring and demolding, the concrete surface of the lining end has a smooth appearance, and the position of the waterstop is accurate, which can ensure that the middle hollow circle coincides with the center line of the deformation joint. The waterstop can also avoid rolling, kinking, unevenness and other phenomena, so that the waterstop can achieve the effect in lining waterproofing and drainage. It can effectively solve the problem of difficulty in positioning the waterstop in the circumferential and longitudinal construction joints of the tunnel. Such as Fig.11 shown.

[0066] Through practical improvement on the traditional grouting equipment with formwork, a modular system of steel end formwork and longitudinal water stop positioning fixture is adopted, which greatly improves the quality of the secondary lining structure concrete. The appearance of the secondary lining concrete after demoulding is shown in the figure below. Fig.12 shown.

[0067] The above are only preferred embodiments of the present invention, which are only used to help understand the method and core ideas of the present application. The protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

[0068] The above embodiments can be implemented in whole or in part by software or hardware. When implemented using software, the above embodiments can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions or computer programs. When a computer instruction or computer program is loaded or executed on a computer, a process or function according to an embodiment of the present application is generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. Computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another computer-readable storage medium.

[0069] The present invention solves the problems in the prior art that, during the concrete pouring process of the permanent lining structure, the voids and hollowing out behind the arch are common quality problems of the tunnel. During the trolley design process, it is considered that when pouring the secondary lining arch concrete, the arch concrete is not poured densely due to workers' observation errors, untimely pumping of materials, etc., thus causing the void and hollowing out. By improving the practicality of the traditional equipment for grouting with a mold, a combined module system of a steel end mold and a longitudinal waterstop positioning fixture is adopted, corresponding technical measures for controlling quality are proposed, the trolley top mold of the secondary lining template trolley is used as the template for grouting, and a liquid level relay is used to perform real-time detection of the compactness of the tunnel arch concrete, thereby saving grouting operation time and improving the construction quality of the secondary lining structure.

Claims

1. A new type of casting method for secondary lining layered casting trolley, characterized in that: The trolley includes a walking mechanism assembly, a gantry assembly, a template assembly, an electrical operation control system, a hydraulic system, an anti-emptying warning system, a vault with mold grouting system, a chute window-by-window mold entry system, and a steel end mold and longitudinal water stop belt positioning fixture combined module system; The walking mechanism assembly includes two driving wheel trolleys and two passive wheel trolleys, which are respectively installed under two walking beams on both sides; The gantry assembly is composed of six gantry frames. The outer side of the column is provided with a screw supporting a single-side wall template and four sets of cylinders for adjusting the side templates. The upper part of the gantry is a working platform. The working platform is provided with a template translation device for operating a hydraulic valve to make the template translate left and right as a whole. There are also four arch template lifting cylinders and a hydraulic operating table. The template assembly is composed of an arch template and two side templates on the circumference, which are connected by bolts in the length direction to form a template of a required length. The side template is connected to the arch top template by a hinge, and the side template can rotate around the hinge to adjust the expansion and contraction of the template to meet the requirements of the cross-section lining. The hydraulic system is composed of a hydraulic control panel, four lifting cylinders, four sets of side template adjustment cylinders, four translation template cylinders and various valves and pipelines; The method of the chute window-by-window feeding system is: by combining the main hopper, the main chute, the three-way diversion chute, the diversion string tube and the window feeding chute, by operating the corresponding gate valve, the concrete flows to each working window, and is used for the window-by-window feeding and pouring of the secondary lining arch wall concrete; The specific method of the vault mold grouting system comprises the following steps: S1, mounting flange with hole opening on the top plate of the trolley; S2, install RPC grouting pipe and exhaust pipe to support the waterproof board; S3, record the buried length of the RPC pipe on the recording board; S4, pouring concrete and observing the slurry coming out of the embedded pipe; S5, the end of the grouting pipe is connected to the grouting machine pipe; S6, grouting liquid preparation and grouting with mold; S7, observe the pressure gauge and the slurry discharge from the exhaust hole; S8, if the vent hole discharges thick slurry, go to S9; if the vent hole does not discharge thick slurry, determine whether the pressure is less than 1.0Mpa, if the pressure is less than 1.0Mpa, go to S6, if the pressure is not less than 1.0Mpa, go to S5 and transfer to the spare grouting hole; S9, grouting is completed, and the hose of the grouting machine is removed; S10, remove the positioning flange after the slurry initially sets.

2. The casting method of the new secondary lining layered casting trolley according to claim 1 is characterized in that: The hydraulic control panel comprises a motor, an oil pump, a filter and an eight-way valve.

3. The casting method of the new secondary lining layered casting trolley according to claim 1 is characterized in that: Said The spare slurry outlet hole in S8 is the middle exhaust hole on the top plate of the trolley.

4. The casting method of the new secondary lining layered casting trolley according to claim 1 is characterized in that: The grouting material in the vault formwork grouting system adopts high-fluidity micro-expansion early-strength filling mortar.

5. The casting method of the new secondary lining layered casting trolley according to claim 4 is characterized in that: The filling mortar meets the requirements of no water bleeding, slight expansion, early strength, high strength, excellent self-leveling performance and long construction time.

6. The casting method of the new secondary lining layered casting trolley according to claim 1 is characterized in that: The steel end mold and longitudinal waterstop positioning fixture combined module system is: the waterstop positioning fixture is improved to assist the installation of the waterstop, and the steel end mold is firmly welded and fixed to the arc-shaped template of the lining trolley.

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