Full-structure repairing method for replacing reinforced concrete pipeline with nodular cast iron pipe short pipe

Abstract

The invention discloses a full-structure repairing method for replacing a reinforced concrete pipeline with a nodular cast iron pipe short pipe, and belongs to the field of pipeline non-excavation construction. The method comprises the steps that after early-stage preparation work is finished, a closed circuit television detection robot is adopted for detecting a to-be-repaired pipeline; a three-dimensional model is generated according to the detected inner diameter of the pipeline and deflection angle data between pipe joints, and a jacking route is determined; the milling and jacking integrated equipment is installed according to data detected by the closed circuit television detection robot; according to the three-dimensional model and the jacking route, the milling and jacking integrated equipment is used for milling, expanding the diameter and guiding and jacking; a newly-crossed nodular cast iron pipeline is installed; after jacking is completed, the milling and jacking integrated equipment is dismantled; a gap between the original reinforced concrete pipe and the newly-penetrated nodular cast iron pipe is filled with a grouting material; and later-stage repair ending work is carried out. According to the method, under the condition that the overflowing capacity is guaranteed, the original pipeline can be completely repaired, and the service life of the newly replaced pipeline can reach 70 years after the pipeline is repaired.

Description

Technical Field

[0001] The invention relates to the technical field of trenchless pipeline technology, in particular to a full-structure repair method for replacing a reinforced concrete pipeline with a short ductile iron pipe. Background Art

[0002] The aging reinforced concrete pipeline network, constructed before the 1990s, has largely exceeded the lifespan of its materials. These pipelines are distributed throughout the city, and traditional open-cut repair methods significantly impact the surrounding environment. Firstly, some site conditions prohibit open-cut repairs, and secondly, the overall cost of such repairs is prohibitive.

[0003] There are five existing methods for trenchless repair of reinforced concrete pipes: (1) replacement of short steel pipes; (2) thermoplastic molding repair; (3) UV curing repair; (4) stainless steel lining repair; and (5) spraying repair. The above five methods use different tools or machines, have different costs, and have different advantages and disadvantages. Only the short steel pipe replacement repair method is a full structural repair method, but it uses welding connections, which are prone to getting stuck during jacking, thus having a greater impact on pipe diameter loss. In addition, the steel pipe material is prone to corrosion, which will reduce the service life of the steel pipe. The other repair methods are all non-full structural repairs, relying on the structural strength of the old pipe. The old pipe itself has problems with its structure, and its service life is greatly reduced after repair.

[0004] In view of this, it is necessary to provide a new full-structure repair method for pipeline trenchless repair with high safety and long service life. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a full-structure repair method for replacing reinforced concrete pipes with short ductile iron pipes. While ensuring the flow capacity, the original reinforced concrete pipes are milled and expanded, and new ductile iron pipes are inserted into the pipes to fully repair the original pipelines. After the repair, the service life of the new replacement pipes can reach 70 years.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0007] A full-structure repair method for replacing a reinforced concrete pipe with a short ductile iron pipe comprises the following steps:

[0008] Step 1: After the preliminary preparations are completed, a closed-circuit television inspection robot is used to inspect the pipeline to be repaired. Based on the detected data of the inner diameter of the pipeline and the deflection angle between the pipe sections, a three-dimensional model is generated and various factors affecting the construction are summarized to finally determine the jacking route;

[0009] Step 2: Install the integrated milling and jacking equipment based on the data detected by the CCTV detection robot;

[0010] Step 3: Based on the jacking route, the integrated milling and jacking equipment mills and expands the diameter and guides the jacking;

[0011] Step 4: Expand the diameter by milling and guide the new ductile iron pipe to pass through;

[0012] Step 5: After all newly-crossed ductile iron pipes are jacked, the integrated milling and jacking equipment is removed from the receiving well;

[0013] Step 6: Fill the gap between the original reinforced concrete pipe and the new ductile iron pipe with grouting material;

[0014] Step 7: Post-repair finishing work.

[0015] A further improvement of the technical solution of the present invention is that: in step 1, the preliminary preparation work specifically includes the following steps:

[0016] Step 1.1, survey the inside of the pipeline to be repaired;

[0017] Step 1.2: Use a water- and pressure-carrying inspection robot to conduct a preliminary exploration of the pipeline to be repaired;

[0018] Step 1.3: Determine the feasibility of the project based on the preliminary exploration results and formulate a construction plan;

[0019] Step 1.44: excavate a working well and a receiving well according to the construction plan. The walls of the working well and the receiving well are cast to wrap the pipeline to be repaired into a whole;

[0020] Step 1.5: Cut off the pipe to be repaired, drain the water and clean the inner wall.

[0021] A further improvement of the technical solution of the present invention is that: in step 1.1, when surveying the pipeline to be repaired, it is necessary to conduct a survey on the pipeline to be repaired in combination with the original design, construction, and operation and maintenance records to determine the burial depth and connection status of the original pipeline, and to survey the underground pipeline obstacles within the range of working wells and receiving wells that need to be set up on site.

[0022] A further improvement of the technical solution of the present invention is that in step 1.2, a water- and pressure-carrying inspection robot is deployed from the exhaust valve of the pipeline to be repaired. After being deployed into the pipeline, the situation inside the entire pipeline is initially explored along the pipeline to understand the problems in each section of the pipeline and detect the actual situation of the original pipeline; it is also necessary to detect whether there are tees and valves outside the design drawings.

[0023] A further improvement of the technical solution of the present invention is that in step 1, the closed-circuit television detection robot has video imaging and laser scanning functions, which can accurately measure the distance and fit the deflection angle between pipelines, fit the three-dimensional model of the original pipeline, and finally form the jacking route.

[0024] A further improvement of the technical solution of the present invention is that: in step 2, when the integrated milling and jacking equipment is installed, the rear backrest, the jacking bracket, the main jacking cylinder, the guide rail bracket, the guide rail, the front sealing device, the front sealing and cutterhead connection compartment, the milling cutterhead, the milling working section, the working feed system and the rear walking section are installed in sequence according to the data detected by the closed-circuit television detection robot;

[0025] The feed system can adjust the posture of the integrated milling and jacking equipment; by adjusting the posture of the integrated milling and jacking equipment, the milling cutter head mills the pipe wall of the pipe to be repaired according to the trajectory of the jacking route.

[0026] A further improvement of the technical solution of the present invention is that: in step 3, when the integrated milling and jacking equipment guides the jacking: the support shoes are opened to provide support force to the working feed system, and the working feed system adjusts the equipment posture so that the milling cutter head mills and expands the pipe to be repaired according to the jacking route, so that the pipe wall of the pipe to be repaired meets the requirements of the jacking route, and the main jacking cylinder starts to jack forward to newly pass through the ductile iron pipe; the steel concrete debris milled is discharged into the mud sedimentation tank outside the receiving well through the slag discharge system.

[0027] A further improvement of the technical solution of the present invention is that: in step 4, after the rear walking section in the integrated milling and jacking equipment enters the pipeline to be repaired, the first section of the new ductile iron pipe is installed when 300 mm of the working well is exposed, and the jacking is continued; when the outermost end of the first section of the new ductile iron pipe is 300 mm away, an "L"-shaped retaining ring is installed as a tooling, and then the next section of the new ductile iron pipe is installed and the jacking is continued; this step is repeated until the jacking is completed.

[0028] A further improvement to the technical solution of the present invention is that in step 5, after the jacking of the newly crossed ductile iron pipe is completed, the following are dismantled in sequence: the front sealing device, the front sealing and cutterhead connection chamber, the milling cutterhead, the milling working section, the working feed system, the rear walking section and the support shoe, and the entire machine is hoisted out of the receiving well and removed from the site; the annular jacking iron, the main jacking cylinder, the guide rail, the guide rail bracket, the jacking bracket and the rear backrest are hoisted out of the working well and removed from the site.

[0029] A further improvement of the technical solution of the present invention is that in step 7, the post-repair finishing work specifically includes the following steps:

[0030] Step 7.1: Perform a pressure test and pipeline flushing on the newly-crossed ductile iron pipeline;

[0031] Step 7.2: connect the new ductile iron pipe to the two original steel pipes in the original pipe;

[0032] Step 7.3: Restore the road surface and clean up the site.

[0033] Due to the adoption of the above technical solution, the technical advancements achieved by the present invention are:

[0034] 1. The present invention detects the original pipeline in combination with the original pipeline drawing, generates a three-dimensional model through the detection data, determines the reasonable milling and diameter expansion route, uses the integrated milling and jacking equipment to mill and expand the concrete pipe of the original pipeline, and jacks in the new ductile iron pipe. The gap between the new ductile iron pipe and the original pipe is grout-filled, and the newly jacked ductile iron pipe is connected to the original pipe after the pressure test is qualified; by maximizing the diameter of the newly replaced ductile iron pipe, the new ductile iron pipe is inserted, and the original pipeline can be fully structurally repaired while ensuring the flow capacity. After the repair, the service life of the new replacement pipe can reach 70 years. It is also applicable to pipes made of other materials such as gray iron pipes and can be promoted for use.

[0035] 2. By putting a water-carrying and pressure-carrying detection robot into the original pipeline, the present invention can detect the situation inside the pipeline while the pipeline maintains normal production and water supply, which is conducive to determining the water outage plan and the location of the working well in advance during later renovations.

[0036] 3. The present invention uses a closed-circuit television detection robot to inspect the original pipeline, generates a three-dimensional model based on the detected pipeline inner diameter and deflection angle data between pipe sections, determines the jacking route, and provides data support for the guided jacking system.

[0037] 4. The present invention uses integrated milling and jacking equipment to adjust the cutter head angle and perform milling and diameter expansion on the original pipeline according to the set route.

[0038] 5. The present invention adopts a new structural form of passing through ductile iron pipes and sets an L-shaped retaining ring between the spigot and the socket bearing surface, so that the bearing surface can withstand sufficient top force according to construction requirements.

[0039] 6. The present invention combines the characteristics of the flexible socket joint of ductile iron pipe: good sealing performance, strong pressure bearing capacity, the deflection angle between pipe sections can reach 2°, easy installation, and a high construction speed of up to 30m / day. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive efforts.

[0041] Figure 1 This is a schematic diagram of a water and pressure detection robot according to an embodiment of the present invention;

[0042] Figure 2 This is a schematic diagram of the working well and receiving well structure in an embodiment of the present invention;

[0043] Figure 3 Schematic diagram of a pipeline inspection robot using CCTV in an embodiment of the present invention;

[0044] Figure 4 3D model schematic diagram of the original reinforced concrete pipeline in the embodiment of the present invention;

[0045] Figure 5 This is a schematic diagram of the jacking route in an embodiment of the present invention;

[0046] Figure 6 Schematic diagram of integrated milling and jacking equipment in an embodiment of the present invention;

[0047] Figure 7 Schematic diagram of a slag discharge system according to an embodiment of the present invention;

[0048] Figure 8 Schematic diagram of the socket and L-shaped retaining ring structure of the new ductile iron pipe in the embodiment of the present invention;

[0049] Figure 9 This is a schematic diagram of the connection between the new ductile iron pipe and the original DN1800 steel pipe in an embodiment of the present invention;

[0050] Among them, 1. Pipeline to be repaired; 1-1. Exhaust valve; 1-2. Pipe wall; 2. Water and pressure detection robot; 2-1. Cable; 3. Working well; 4. Receiving well; 5. Newly crossed ductile iron pipe; 5-1. Socket; 5-2. Socket stress surface; 6. CCTV detection robot; 7. Front sealing device; 8. Front sealing and cutterhead connection compartment; 9. Milling cutterhead; 10. Milling working section; 11. Feed system; 12. Rear walking section; 13. Support shoe; 14. Lubrication grouting hole; 15. Ring top iron; 16. Main top cylinder; 17. Guide rail; 18. Guide rail bracket; 19. Push bracket; 20. Rear backrest; 21. Slag discharge system; 22. Slag discharge port; 23. Mud sedimentation tank; 24. Slag discharge pipe; 25. Retaining ring; 26. Original steel pipe. DETAILED DESCRIPTION

[0051] It should be noted that the terms "including" and "having" and any variations thereof in the specification and claims of the present invention and the above-mentioned drawings are intended to cover non-exclusive inclusions. For example, a process, method, system, product or apparatus comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or are inherent to these processes, methods, products or apparatuses.

[0052] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0053] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments:

[0054] like Figure 1-9 As shown, a full structural repair method for replacing a reinforced concrete pipe with a short ductile iron pipe comprises the following steps:

[0055] Step 1: After the preliminary preparation work is completed, a closed-circuit television inspection robot 6 is used to inspect the pipeline 1 to be repaired. A three-dimensional model is generated based on the detected pipeline inner diameter and deflection angle data between pipe sections, and various factors affecting the construction are summarized to finally determine the jacking route;

[0056] Closed-circuit television inspection, the full English name is Closed-Circuit Television Inspection.

[0057] The preliminary preparation work specifically includes the following steps:

[0058] Step 1.1, survey the interior of the pipeline 1 to be repaired;

[0059] Specifically, the pipeline 1 to be repaired generally includes a concrete pipeline and a steel pipeline sheathed in the concrete pipeline, which is usually called a reinforced concrete pipeline.

[0060] A water- and pressure-carrying inspection robot 2 is deployed from the exhaust valve 1-1 of the pipeline 1 to be repaired. After being deployed into the pipeline, the situation inside the entire pipeline is initially explored along the pipeline to understand the problems in each section of the pipeline and detect the actual situation of the original pipeline.

[0061] When surveying the pipeline 1 to be repaired, it is necessary to combine the original design, construction, and operation and maintenance records to determine the buried depth and connection conditions of the original pipeline, and conduct a survey of underground pipeline obstacles within the scope of the working well 3 and receiving well 4 that need to be set up on site.

[0062] Step 1.2: Use the water- and pressure-carrying inspection robot 2 to conduct a preliminary exploration of the pipeline 1 to be repaired;

[0063] Specifically, such as Figure 1 As shown, a water-carrying and pressure-carrying inspection robot 2 is deployed from the exhaust valve 1-1 of the pipeline 1 to be repaired. After being deployed into the pipeline, the water-carrying and pressure-carrying inspection robot 2 is connected to the external power supply through the cable 2-1, and conducts a preliminary exploration of the situation inside the entire pipeline along the pipeline to understand the problems in each section of the pipeline and detect the actual situation of the original pipeline; the water-carrying and pressure-carrying inspection robot 2 is used to perform an endoscopy on the pipeline 1 to be repaired to detect whether there are tees and valves outside the design drawings.

[0064] Step 1.3: Determine the feasibility of the project based on the preliminary exploration results and formulate a construction plan;

[0065] Specifically, the feasibility of the project is determined based on the initial test results of the water-carrying and pressure-carrying detection robot 2, a construction plan is formulated, and a reliable water diversion, drainage, traffic guidance and excavation plan for the working well 3 and the receiving well 4 is compiled.

[0066] Step 1.4: excavate the working well 3 and the receiving well 4 according to the construction plan. The walls of the working well 3 and the receiving well 4 will wrap and cast the pipeline 1 to be repaired into a whole; Figure 2 As shown,

[0067] Step 1.5: Cut off the pipe 1 to be repaired to drain the water and clean the inner wall.

[0068] Specifically, the upstream and downstream valves and related valves of the pipeline 1 to be repaired are closed, the concrete pipeline is cut off along the inner wall of the working well 3, and the water in the pipeline 1 to be repaired is discharged to a designated location.

[0069] The inner wall of the pipeline 1 to be repaired is cleaned, and attachments that affect the detection of the closed-circuit television detection robot 6 need to be cleaned.

[0070] like Figure 3 As shown, the CCTV detection robot 6 has video imaging and laser scanning functions, which can accurately measure the distance and fit the deflection angle between pipelines, and fit the three-dimensional model of the original pipeline, as shown in FIG. Figure 4 As shown, the top routing is finally formed, such as Figure 5 shown.

[0071] Step 2: Install the integrated milling and jacking equipment based on the data detected by the CCTV detection robot 6;

[0072] Specifically, such as Figure 6 As shown, the integrated milling and jacking equipment is used in underground engineering, typically for tunneling or pipe laying, and is capable of efficient and stable excavation operations in underground projects. It includes a front seal 7, a front seal and cutterhead connection compartment 8, a milling cutterhead 9, a milling working section 10, a feed system 11, a rear travel section 12, grippers 13, lubrication grouting holes 14, an annular jacking iron 15, a main jacking cylinder 16, a guide rail 17, a guide rail bracket 18, a jacking bracket 19, and a rear backrest 20.

[0073] The front sealing device 7 is located at the front end of the equipment and is used to prevent mud and water from entering the interior of the equipment during the jacking process of the equipment.

[0074] The front seal and cutter head connecting chamber 8 is a structural part connecting the front seal device 7 and the milling cutter head 8, and may be used to support and protect the seal device.

[0075] The milling cutter head 9 is the cutting part of the equipment, which is used to cut the soil layer or rock so that the equipment can move forward.

[0076] The milling section 10 includes the milling cutter head 9 and other related cutting tools, and is the main area where the equipment performs cutting operations.

[0077] The feed system 11 is a system for controlling the advancement and cutting of the equipment, including hydraulic or mechanical transmission devices.

[0078] The rear walking section 12 is the walking mechanism at the rear of the equipment, which is used to support the weight of the equipment and help the equipment move in the tunnel.

[0079] The support shoe 13 is installed on the rear walking section 12 to support the equipment during the jacking process to prevent the equipment from sinking.

[0080] The lubrication grouting holes 14 are used to inject lubricant or grouting material into the area around the equipment to reduce friction and stabilize the surrounding soil layer.

[0081] The annular jacking iron 15 is located at the rear of the equipment and is used to evenly distribute the jacking force to prevent the equipment from shifting during the jacking process.

[0082] The main jacking cylinder 16 is the main hydraulic cylinder that provides jacking force and is used to push the equipment forward.

[0083] The guide rail 17 is mounted on a guide rail bracket 18 and is used to guide the equipment to move linearly in the tunnel.

[0084] The guide rail bracket 18 is a structure that supports the guide rail 17 to ensure the stability of the guide rail 17.

[0085] The jacking bracket 19 is a structure that supports the main jacking cylinder 16 and the annular jacking iron 15 to ensure that the jacking force is evenly distributed.

[0086] The rear backrest 20 is located at the rear of the device and is used to support the device and prevent the device from falling back during the jacking process.

[0087] When installing the integrated milling and jacking equipment, the rear backrest 20, jacking bracket 19, main jacking cylinder 16, guide rail bracket 18, guide rail 17, front sealing device 7, front seal and cutter disc connection chamber 8, milling cutter disc 9, milling working section 10, working feed system 11 and rear walking section 12 are installed in sequence according to the data detected by the closed-circuit television detection robot 6.

[0088] The feed system 11 can adjust the posture of the integrated milling and jacking equipment; by adjusting the posture of the integrated milling and jacking equipment, the milling cutter head 9 mills the pipe wall 1-2 of the pipe 1 to be repaired according to the trajectory of the jacking route.

[0089] Step 3: Based on the jacking route, the integrated milling and jacking equipment mills and expands the diameter and guides the jacking;

[0090] Specifically, when the integrated milling and jacking equipment guides the jacking: the support shoe 13 is opened to provide support force to the work feed system 11, and the work feed system 11 adjusts the equipment posture so that the milling cutter head 9 mills and expands the pipe 1 to be repaired according to the jacking route, so that the pipe wall 1-2 of the pipe 1 to be repaired meets the requirements of the jacking route, and the main jacking cylinder 16 starts to jack forward to newly pass through the ductile iron pipe 5; the steel concrete debris under milling is collected at the slag discharge port 22, and is discharged from the slag discharge pipe 24 through the slag discharge system 21 to the mud sedimentation tank 23 outside the receiving well 4, such as Figure 7 shown.

[0091] Step 4: Expand the diameter by milling and guide the new ductile iron pipe to pass through;

[0092] Specifically, a newly crossed ductile iron pipe generally includes several sections of newly crossed ductile iron pipes 5. After the rear walking section 12 in the integrated milling and jacking equipment enters the pipe 1 to be repaired, the first section of the newly crossed ductile iron pipe 5 is installed when the working well is exposed to 3300mm, and the jacking is continued; when the outermost end of the first section of the newly crossed ductile iron pipe 5 has a remaining distance of 300mm, an "L"-shaped retaining ring 25 is installed as a tool, and then the next section of the newly crossed ductile iron pipe 5 is installed, and the jacking is continued; this step is repeated until the jacking is completed. Figure 8 As shown, the retaining ring 25 is arranged between the socket bearing surface 5 - 2 of the previous section of the newly passed ductile iron pipe 5 and the socket 5 - 1 of the next section of the newly passed ductile iron pipe 5 .

[0093] Step 5: After all the newly-crossed ductile iron pipes 5 are jacked, the integrated milling and jacking equipment is removed from the receiving well;

[0094] Specifically, after the jacking of all the newly crossing ductile iron pipes 5 is completed, the following are dismantled in sequence: the front sealing device 7, the front sealing and cutterhead connection chamber 8, the milling cutterhead 9, the milling working section 10, the working feed system 11, the rear walking section 12 and the support shoe 13, and the entire machine is hoisted out of the receiving well 4 and removed from the site; the annular jacking iron 15, the main jacking cylinder 16, the guide rail 17, the guide rail bracket 18, the jacking bracket 19 and the rear backrest 20 are hoisted out of the working well 3 and removed from the site.

[0095] Step 6: Fill the gap between the original reinforced concrete pipe and the new ductile iron pipe with grouting material;

[0096] Step 7: Post-repair finishing work.

[0097] The specific steps include:

[0098] Step 7.1: Perform a pressure test and pipeline flushing on the newly-crossed ductile iron pipeline;

[0099] Step 7.2, as Figure 9 As shown, the new ductile iron pipe is connected to the two original steel pipes 26 in the original pipe;

[0100] Step 7.3: Restore the road surface and clean up the site.

[0101] Example 1

[0102] In a renovation and upgrading project for an old water supply network in a certain city, a full-structure repair method provided by the present invention, which uses short ductile iron pipes to replace reinforced concrete pipes, was used to renovate the water supply network.

[0103] The project targets the existing DN1000 reinforced concrete pipe, starting from Dapu Road in the north, connecting to the existing DN1000 concrete pipe (with a DN950 ductile iron pipe inserted for double-insertion repair) and ending at Jianxue Street in the south, with a total length of 531.1 meters. It will be connected to the existing DN1000 steel pipe.

[0104] The specific construction steps are as follows:

[0105] 1. Construction preparation:

[0106] Drawings and documentation of the existing DN1000 reinforced concrete pipeline for this section of road indicate that the pipeline was laid in November 1988. Jianxue Street in the south is connected to the existing DN1000 steel pipe, while Dapu Road in the north is connected to the existing gray cast iron pipe. A DN150 vent is located at the north end. A water- and pressure-testing robot was deployed at this location to conduct an initial test of the existing pipeline. A tee was found 241 meters from the starting point of Dapu Road in the north.

[0107] In conjunction with the operation of the entire water supply network, water supply to this section of the pipeline can be shut off by closing the DN1000 valve upstream of Dapu Road and the DN1000 gate valve downstream of Jianxue Street. This pipeline is located on the west side of the main road, requiring half of the main road to be closed during construction.

[0108] 2. Working shaft: 6m long, 3m wide, 3.1m deep; receiving shaft: 6m long, 2.8m wide, 3.1m deep. Both adopt an open-cut brick-concrete structure with steel reinforcement on the inner walls. Construction time: 10 days.

[0109] 3. After the upstream and downstream valves on the pipe wall are closed, the pipes are cut off to drain the water into the surrounding rainwater wells.

[0110] 4. Clean the inner wall of the original DN1000 reinforced concrete pipe to meet the detection conditions of the closed-circuit television detection robot.

[0111] 5. Use a CCTV inspection robot to inspect the existing reinforced concrete pipes. The inspection time is 10 hours.

[0112] 6. Install the integrated milling and jacking equipment, the construction time is 2 days.

[0113] 7. Guided jacking:

[0114] Construction crew: 8. Construction machinery: 1 gantry crane. 176 3m long DN1000 ductile iron pipes, and 175 sets of "L"-shaped retaining rings.

[0115] The milling and jacking equipment was used to mill the existing reinforced concrete pipe according to the designed route. Simultaneously, the milling and jacking equipment and the ductile iron pipe were jacked into the existing reinforced concrete pipe. L-shaped retaining rings were added during the installation of the ductile iron pipe. The jacking was completed in 21 days.

[0116] 8. Remove the integrated milling and jacking equipment one by one and hoist it out of the working pit. The construction time is 2 days.

[0117] 9. Grouting Construction: 8 workers. Materials: 0.3m cement brick, 100kg cement, 50kg leak-proof sealant, 100t grouting material, 4 DN50 pipe thread ends, 4 DN50 valves. Equipment: 1 grouting pump, 1 mixer.

[0118] Fill the gaps between the existing reinforced concrete pipes in the working and receiving wells and the newly crossed ductile iron pipes with bricks, leak-proof sealants, and cement. Reserve grouting holes and top vents. Use a grouting pump to inject grouting material through the reserved grouting holes in the working well to fill the gap between the two pipes.

[0119] 10. A crane and five construction workers installed the pressure testing equipment, completing the 24-hour work. Approximately 300 tons of water were injected into the newly-crossed ductile iron pipeline, a 16-hour operation. The pipeline was pressure tested according to pressure testing specifications, initially increasing the pressure to 0.4 MPa and then gradually increasing it to 0.9 MPa. After stabilizing, the pressure was maintained for 30 minutes, and the test was completed. The pressure was then reduced to the pipeline's operating pressure of 0.4 MPa and maintained for 30 minutes. The entire pressure testing process was successful.

[0120] 11. Clean the new ductile iron pipeline.

[0121] 12. Connect the new ductile iron pipe to the existing pipes at both ends.

[0122] 13. Backfill, restore facilities, and clean up the site.

[0123] Example 2

[0124] In an industrial park where a company is located, an 80m DN2000 reinforced concrete pipeline was buried and needed to be repaired by inserting a DN1800 ductile iron pipe inside. The construction was carried out according to a full-structure repair method provided by the present invention, which uses a short ductile iron pipe to replace the reinforced concrete pipeline.

[0125] The specific steps are as follows:

[0126] 1. Construction preparation:

[0127] 1) The length of the original DN2000 reinforced concrete pipeline to be repaired is 80m, and the buried depth at the center of the pipeline is -3.2m to 3.5m.

[0128] 2) Because there is no water flowing through the pipeline, the water- and pressure-carrying inspection robot is manually lifted to simulate a preliminary inspection of the situation inside the pipeline.

[0129] 3) Determine the feasibility of the project based on the preliminary survey results. Based on the site conditions, build a concrete working pit with a length, width, and height of 6m*6m*5m, and a steel structure receiving pit with a length, width, and height of 6m*6m*5m.

[0130] 2. Construction of the working and receiving wells: Based on the drawings drawn by the design institute, the working and receiving wells were constructed using open excavation. The construction period was 20 days, and the construction of the working and receiving wells was completed.

[0131] 3. Pipeline disconnection and drainage: The original pipeline here is in a water-free state, so this step can be omitted.

[0132] 4. Clean the inner wall of the original pipeline: clean the attachments on the inner wall of the pipeline that affect the CCTV detection robot.

[0133] 5. Use a closed-circuit television inspection robot (wheeled underground pipeline inspection robot) to inspect the original reinforced concrete pipeline. The inspection results are shown in Table 1 below.

[0134] Table 1 Detailed list of deflection angle data between pipe segments

[0135]

[0136]

[0137] The three-dimensional coordinate data of the pipeline are shown in Table 2.

[0138] Table 2 Detailed list of pipeline three-dimensional coordinate data

[0139]

[0140]

[0141] Generate a three-dimensional model based on the detected pipe inner diameter and deflection angle data between pipe segments, such as Figure 4 As shown, determine the top route, such as Figure 5 shown.

[0142] 6. Install integrated milling and jacking equipment for guided jacking, such as Figure 6 shown.

[0143] Construction personnel: 6 people. Construction machinery: 1 50t crane.

[0144] Based on the data collected by the CCTV inspection robot, the rear backrest, push bracket, and main jacking cylinder were installed in sequence. The guide rail bracket, guide rail, front seal, front seal and cutterhead connection compartment were installed, followed by the milling cutterhead, milling section, feed system, and rear travel section. The construction took three days.

[0145] 7. Guided jacking:

[0146] Construction crew: 8 people. Construction machinery: 1 25t crane. 80m of ductile iron pipe, 23 sets of "L"-shaped retaining rings.

[0147] According to the jacking route, the milling and jacking integrated equipment is used to mill the original reinforced concrete pipe.

[0148] 8. Simultaneous milling and jacking equipment were used to jack the ductile iron pipe into the existing reinforced concrete pipeline. An L-shaped retaining ring was added during the installation of the ductile iron pipe. The jacking was completed in 6 days.

[0149] 9. Remove the integrated milling and jacking equipment one by one and hoist it out of the working pit. The construction time is 2 days.

[0150] 10. Grouting construction:

[0151] Construction workers: 8 people. Materials: Cement bricks 0.3m 3 , 100kg cement, 50kg leak-proof sealant, 100t grouting material, 4 DN50 pipe thread heads, 4 DN50 valves. Equipment: 1 grouting pump, 1 mixer.

[0152] Fill the gaps between the existing reinforced concrete pipes in the working and receiving wells and the newly crossed ductile iron pipes with bricks, leak-proof sealants, and cement. Reserve grouting holes and top vents. Use a grouting pump to inject grouting material through the reserved grouting holes in the working well to fill the gap between the two pipes.

[0153] 11. A crane and five construction workers installed the pressure testing tooling, and the construction time was 24 hours. About 200 tons of water was injected into the new ductile iron pipeline, which took 11 hours. The pipeline was pressure tested according to the pressure testing specifications, first increasing the pressure to 0.5 MPa, and then gradually increasing the pressure to 10 MPa. After stabilizing the pressure, the pressure was maintained for 30 minutes and the pressure was qualified. Then it was reduced to the pipeline working pressure of 0.5 MPa and maintained for 30 minutes. The entire pressure testing process was qualified. This means that the main steps of the present invention were successfully completed. Pipeline connection construction can be carried out subsequently.

[0154] 12. Flushing of new ductile iron pipes.

[0155] 13. The new ductile iron pipe is connected to the existing pipes at both ends and is omitted (this section of construction is experimental in nature, is not connected to other pipes, and is not an exclusive feature of the present invention).

[0156] 14. Clean up the scene.

[0157] In summary, the present invention eliminates the need for a large amount of ground excavation in the repair of reinforced concrete pipes, effectively reducing the impact on the surrounding traffic environment and the surrounding production and living environment; it can be constructed in sections and nodes, which is more flexible and less affected by natural factors such as temperature and rainfall; taking all factors into consideration, the overall cost is lower, and the social and economic benefits are significant; full structural repair extends the service life by 70 years, which is equivalent to laying new pipes; it adopts socket-type flexible interfaces with good sealing performance, easy installation, fast construction, and a long single-section construction distance, so it can be promoted and used.

[0158] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A full structural repair method for replacing reinforced concrete pipes with short ductile iron pipes, characterized in that: The following steps are involved: Step 1: After the preliminary preparation work is completed, a closed-circuit television inspection robot (6) is used to inspect the pipeline (1) to be repaired. A three-dimensional model is generated based on the detected pipeline inner diameter and deflection angle data between pipe sections, and various factors affecting the construction are summarized to finally determine the jacking route; Step 2, installing the milling and jacking integrated equipment based on the data detected by the closed-circuit television detection robot (6); Step 3: Based on the jacking route, the integrated milling and jacking equipment mills and expands the diameter and guides the jacking; Step 4: Expand the diameter by milling and guide the new ductile iron pipe to pass through; Step 5, after all the newly crossed ductile iron pipes (5) in the newly crossed ductile iron pipeline are pushed in, the milling and pushing integrated equipment is removed from the receiving well; Step 6: Fill the gap between the original reinforced concrete pipe and the new ductile iron pipe with grouting material; Step 7: Post-repair finishing work.

2. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 1, characterized in that: In step 1, the preliminary preparation work specifically includes the following steps: Step 1.1, survey the interior of the pipeline to be repaired (1); Step 1.2, using a water- and pressure-carrying inspection robot (2) to conduct a preliminary exploration inside the pipeline (1) to be repaired; Step 1.3: Determine the feasibility of the project based on the preliminary exploration results and formulate a construction plan; Step 1.44, excavating a working well (3) and a receiving well (4) according to the construction plan, wherein the walls of the working well (3) and the receiving well (4) wrap the pipeline (1) to be repaired and cast them into a whole; Step 1.5: Cut off the pipe (1) to be repaired to drain the water and clean the inner wall.

3. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 2, characterized in that: In step 1.1, when surveying the pipeline (1) to be repaired, it is necessary to combine the original design, construction, and operation and maintenance records to survey the pipeline (1) to be repaired, determine the buried depth and connection conditions of the original pipeline, and survey the underground pipeline obstacles within the scope of the working well (3) and receiving well (4) that need to be set up on site.

4. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 2, characterized in that: In step 1.2, a water- and pressure-carrying inspection robot (2) is deployed from the exhaust valve (1-1) of the pipeline to be repaired (1). After being deployed into the pipeline, the entire pipeline is initially explored along the pipeline to understand the problems in each section of the pipeline and to detect the actual situation of the original pipeline. It is also necessary to detect whether there are tees and valves that are not in the design drawings.

5. The method for full structural repair of a reinforced concrete pipe by replacing a short ductile iron pipe according to claim 1, characterized in that: In step 1, the CCTV detection robot (6) has video imaging and laser scanning functions, and can accurately measure distance and fit the deflection angle between pipelines, fit the three-dimensional model of the original pipeline, and finally form the jacking route.

6. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 1, characterized in that: In step 2, when the milling and jacking integrated equipment is installed, the rear backrest (20), the jacking bracket (19), the main jacking cylinder (16), the guide rail bracket (18), the guide rail (17), the front sealing device (7), the front sealing and cutter head connection chamber (8), the milling cutter head (9), the milling working section (10), the working feed system (11) and the rear walking section (12) are installed in sequence according to the data detected by the closed-circuit television detection robot (6); The feed system (11) can adjust the posture of the integrated milling and jacking device; by adjusting the posture of the integrated milling and jacking device, the milling cutter head (9) mills the pipe wall (1-2) of the pipe (1) to be repaired according to the trajectory of the jacking route.

7. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 1, characterized in that: In step 3, when the integrated milling and jacking equipment guides the jacking, the support shoe (13) is opened to provide support force to the working feed system (11), and the working feed system (11) adjusts the equipment posture so that the milling cutter head (9) mills and expands the pipe (1) to be repaired according to the jacking route, so that the pipe wall (1-2) of the pipe (1) to be repaired meets the requirements of the jacking route, and the main jacking cylinder (16) starts to jack forward to newly pass through the ductile iron pipe (5); the steel concrete debris under milling is discharged into the mud sedimentation tank (23) outside the receiving well (4) through the slag discharge system (21).

8. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 1, characterized in that: In step 4, after the rear walking section (12) of the milling and jacking integrated equipment enters the pipe (1) to be repaired, the first section of the new ductile iron pipe (5) is installed when the exposed working well (3) is 300 mm, and the jacking is continued; when the outermost end of the first section of the new ductile iron pipe (5) is 300 mm away, an "L"-shaped retaining ring (25) is installed as a tool, and then the next section of the new ductile iron pipe (5) is installed and the jacking is continued; this step is repeated until the jacking is completed.

9. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 1, characterized in that: In step 5, after the jacking of all the newly crossed ductile iron pipes (5) is completed, the following parts are dismantled in sequence: the front sealing device (7), the front sealing and cutterhead connection chamber (8), the milling cutterhead (9), the milling working section (10), the working feed system (11), the rear walking section (12) and the support shoe (13), and the entire machine is hoisted out of the receiving well (4) and removed from the site; the annular jacking iron (15), the main jacking cylinder (16), the guide rail (17), the guide rail bracket (18), the jacking bracket (19) and the rear backrest (20) are hoisted out of the working well (3) and removed from the site.

10. The method for full structural repair of a reinforced concrete pipe using a short ductile iron pipe as claimed in claim 1, characterized in that: In step 7, the post-repair finishing work specifically includes the following steps: Step 7.1: Perform a pressure test and pipeline flushing on the newly-crossed ductile iron pipeline; Step 7.2, connecting the new ductile iron pipe to the two original steel pipes (26) in the original pipe; Step 7.3: Restore the road surface and clean up the site.

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