Fabricated front support grouting steel pipe pile reinforcement cushion layer structure and manufacturing method

Abstract

The invention discloses an assembly type front support grouting steel pipe pile reinforcement cushion layer structure and a manufacturing method. The manufacturing method specifically comprises the manufacturing method of an assembly type structure and corresponding installation. Each cushion layer is composed of a front part and a rear part, reinforcing bars and connecting grooves are arranged in each part, and therefore the adjacent cushion layers can be conveniently connected to form an overall force bearing structure. In addition, the surface of the cushion layer is provided with the buckles for hoisting, so that hoisting and fixing during construction are facilitated. In addition, the open grooves matched with the front supporting type grouting steel pipe piles are formed in the cushion layer, so that the cushion layer is conveniently connected with the front supporting type grouting steel pipe piles. The cushion layer is manufactured in an auxiliary mode through a multi-layer splicing mold, and the grooving position, the grooving size, reinforcement composition and the size of the cushion layer can be modified according to actual needs.

Description

Technical Field

[0001] The present invention relates to the technical field of foundation pit support, and in particular to an assembled front-support grouting steel pipe pile reinforcement cushion structure and a manufacturing method thereof. Background Art

[0002] Foundation pit support is a crucial component of foundation pit engineering, and its overall construction quality is crucial. Generally speaking, foundation pit support is a temporary structure, and excessive investment can lead to unnecessary waste. Furthermore, unsafe support structures can easily cause engineering accidents, resulting in casualties, damage to adjacent buildings, and other serious hazards. Therefore, selecting a safe, reasonable, and economical foundation pit support solution is essential.

[0003] The front-support grouting steel pipe support system can effectively improve the efficiency of engineering construction in foundation pit construction. By adopting this support system during the construction process, the probability of deformation and collapse during earth excavation can be reduced, and the safety and stability of construction can be improved. Due to its improved construction efficiency and reduced construction risks, it can save manpower and material resources, thereby reducing the overall construction cost. The amount of materials such as steel bars and concrete used is far less than that of conventional solutions, avoiding the secondary noise and dust pollution to the environment caused by dismantling the support. It has a good green and environmental protection effect and significant comprehensive social benefits. Compared with conventional horizontal internal supports, this process can reduce the difficulty of foundation pit construction, improve work efficiency, shorten construction period, save costs, and provide a reference for the application of similar support technologies.

[0004] In existing construction cases, front-supported grouting steel pipe piles require on-site pouring of a reinforced cushion layer during construction. This presents several drawbacks: 1. Long construction period: On-site reinforcement binding, formwork support, pouring, and curing are required, slowing overall progress; 2. High cost: Large amounts of steel and concrete are required, resulting in high labor and material costs; 3. Difficulty in quality control: Weather-related cracks and leaks are common, and improper construction joint treatment can easily lead to structural defects. Therefore, the proposal is to use prefabricated, assembled cushion modules as an alternative to cast-in-place processes. Prefabricated modules are standardized and factory-produced, allowing for direct on-site assembly. This can shorten construction time by 30%-50%, reduce wet work, and reduce material waste and labor costs, while also improving crack resistance and waterproofing. This makes them particularly suitable for projects with tight deadlines or complex environments. Summary of the Invention

[0005] In order to overcome the defects in the background technology and effectively solve the problem of low recovery efficiency of the front support pile steel pipe mentioned above, the present invention proposes for the first time an assembled front support grouting steel pipe pile reinforcement cushion structure and a manufacturing method.

[0006] An assembled front-support grouting steel pipe pile reinforcement cushion structure and a manufacturing method are characterized in that the reinforcement cushion structure consists of two front and rear blocks, which are spliced around the grouting steel pipe pile, with the rear block close to one side of the foundation pit edge and the front block located on the other side of the front-support grouting steel pipe pile.

[0007] Furthermore, the rear block and the front block are both composed of a casting body, reinforcement, casting pipes and corresponding grouting ports, positioning holes and lifting buckles.

[0008] Furthermore, the mold for making the reinforcement cushion layer is a rectangle formed by four mutually perpendicular modules and has screw holes for fixing with adjacent modules.

[0009] Furthermore, each module is composed of a plurality of units connected up and down, and the height of the cushion layer can be changed by changing the number of connected units.

[0010] Furthermore, holes for placing steel bars are left between the upper and lower molds, and reinforcement and grouting pipelines can be set as needed.

[0011] Furthermore, the uppermost unit is provided with a slide rail, which can cooperate with the sliding platform to set a mold related to the cushion layer characteristics. The characteristic mold includes a pipe mold, a positioning mold and a grouting port.

[0012] Preferably, pipe molds with different diameters and inclinations, different positioning positions, and different numbers of grouting pipes are used according to actual construction needs; the top layer uses different numbers of lifting clips, and reinforced cushion layers under different construction conditions can be produced without changing the mold body.

[0013] Furthermore, the hoisting clips are composed of a row of annular clips fixed to the steel bars, placed in the slot between the top layer and the second layer, and used for hoisting during construction:

[0014] Furthermore, the pipe molds used for the front block and the rear block are a set that cooperate with each other, so that during construction, the gap between the front and rear blocks can surround the front-supported grouting steel pipe pile to form a stable whole.

[0015] Furthermore, the production method includes:

[0016] (1) Install each module from bottom to top and fix adjacent modules;

[0017] (2) Arrange the reinforcement mesh, grouting pipes, lifting clips, pipe molds, grouting ports, and positioning molds in order from bottom to top;

[0018] (3) Inject a certain amount of concrete based on the design plan, and after solidification, remove the following in the following order: pipe mold and positioning hole mold, surrounding mold, and pouring pipe mold;

[0019] Furthermore, the installation method includes:

[0020] (1) Reserve positioning holes in the foundation pit and plan the placement location;

[0021] (2) Use the special clip on one side to hoist the rear block from the gap of the front-supported grouting steel pipe pile to the specified height of the reinforcement cushion layer;

[0022] (3) Lift the other end of the rear block of the reinforced cushion layer by using the lifting buckle on the other side to make the cushion layer flush with the foundation pit, further align the front-supported grouting steel pipe piles and the positioning holes reserved in the foundation pit, and then connect the rear block with the front-supported grouting steel pipe piles and connect it with other adjacent plates;

[0023] (4) Hoist the front block to the corresponding position through a special buckle, connect it to the front support grouting steel pipe pile, and then connect it to other adjacent plates;

[0024] (5) After the adjacent reinforcement cushion layers are installed, grouting is injected into the pouring pipes in the reinforcement cushion layers through the grouting ports to form an integral structure.

[0025] The beneficial effects of the present invention are:

[0026] (1) The present invention can significantly shorten the construction period and reduce wet work, reduce material waste and labor costs, and at the same time improve crack resistance and waterproofness.

[0027] (2) The present invention can be flexibly combined according to different construction projects, and the structural specifications of the prefabricated structure can be changed without adopting new molds, which is flexible in use. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is the back block of the reinforced cushion layer, among which 1 is the contact surface with the front-supported grouting steel pipe pile, 2 is the clip for lifting, 3 is the fixing hole, 4 is the grouting port, 5 is the grouting pipeline, and 6 is the reinforcement mesh.

[0029] Figure 2 This is the mold for making the rear block of the reinforced cushion layer, where 1 is the positioning port, 2 is the slide groove on the top of the unit, 3 is the fixed screw hole, 4 is the reserved hole for fixing the steel mesh between units, 5 is the pipe mold used for the rear block, and 6 is the sliding platform for loading various feature molds.

[0030] Figure 3 It is a sliding platform, where 1 is a platform connected to the feature mold, 2 is a tightening bolt, which fixes the sliding platform on the slide rail through downward pressure when fixing, and 3 is a parallel pulley, which is tangent to the slide rail at the inside.

[0031] Figure 4 This is the second step of the installation method of the reinforced cushion layer. The reinforced cushion layer is hoisted to the specified height, where 1 is the edge of the foundation pit, 2 is the reinforced cushion layer, and 3 is the bottom of the foundation pit.

[0032] Figure 5This is the third step of the installation method of the reinforced cushion layer. The other end of the rear block of the reinforced cushion layer is lifted by the lifting buckle on the other side, and the rear block of the reinforced cushion layer is moved into position, where 1 is the edge of the foundation pit, 2 is the reinforced cushion layer, and 3 is the bottom of the foundation pit.

[0033] Figure 6 This is the fourth step of the installation method of the reinforced cushion layer. Lift the other end of the rear block of the reinforced cushion layer through the lifting buckle on the other side, and move the rear block of the reinforced cushion layer into position, where 1 is the edge of the foundation pit, 2 is the reinforced cushion layer, and 3 is the bottom of the foundation pit.

[0034] Figure 7 This is the fifth step of the installation method of the reinforced cushion layer. The front block is hoisted to the corresponding position through a special clip, connected to the front-supported grouting steel pipe pile, and then connected to other adjacent plates. Among them, 1 is the edge of the foundation pit, 2 is the reinforced cushion layer, and 3 is the bottom of the foundation pit.

[0035] Figure 8 It is a construction flow chart of the present invention. DETAILED DESCRIPTION

[0036] The specific embodiments of the present invention are described in detail below with reference to the accompanying drawings. It should be pointed out that the embodiments are only specific explanations of the invention and should not be regarded as limitations of the invention. The purpose of the embodiments is to enable those skilled in the art to better understand and reproduce the technical solutions of the present invention. The scope of protection of the present invention shall still be based on the scope defined by the claims.

[0037] Refer to the attached Figure 1-8 .

[0038] This embodiment provides a prefabricated front support grouting steel pipe pile reinforcement cushion structure and a manufacturing method, Figure 1-7 The structure of the reinforced cushion layer consists of a front block and a rear block, which are spliced around the grouting steel pipe piles. The rear block is close to one side of the edge of the foundation pit, and the front block is located on the other side of the front-supported grouting steel pipe piles.

[0039] The front block and the rear block are both composed of a casting body, reinforcement, a casting pipe and corresponding grouting ports, positioning holes and lifting buckles.

[0040] The mold for making the reinforcement cushion layer is a rectangle formed by four mutually perpendicular modules and has screw holes for fixing with adjacent modules.

[0041] The module is composed of a plurality of units connected up and down, and the height of the cushion layer can be changed by changing the number of connected units.

[0042] Holes for placing steel bars are left between the upper and lower molds, and reinforcement and grouting pipelines can be set as needed.

[0043] The uppermost unit is provided with a slide rail, which can cooperate with the sliding platform to set the mold of the cushion layer characteristics. The characteristic mold includes a pipe mold, a positioning mold and a grouting port.

[0044] The uppermost unit adopts different numbers of lifting clips, and can produce reinforcement cushion layers under different construction conditions without changing the mold body.

[0045] The hoisting clips are composed of a row of annular clips fixed to the steel bars, which are placed in a slot between the top layer and the second layer for hoisting during construction.

[0046] The pipe molds used for the front block and the rear block are a group that cooperate with each other, so that during construction, the gap between the front and rear blocks can surround the front-supported grouting steel pipe pile to form a stable whole.

[0047] The production method comprises:

[0048] (1) Install each module from bottom to top and fix adjacent modules;

[0049] (2) Arrange the reinforcement mesh, grouting pipes, lifting clips, pipe molds, grouting ports, and positioning molds in order from bottom to top;

[0050] (3) Inject a certain amount of concrete based on the design plan, and after solidification, remove the following in the following order: pipe mold and positioning hole mold, surrounding mold, and casting pipe mold.

[0051] As shown in the figure, the construction method of the present invention is:

[0052] (1) Reserve positioning holes in the foundation pit and plan the placement location;

[0053] (2) Use the special clip on one side to hoist the rear block from the gap of the front-supported grouting steel pipe pile to the specified height of the reinforcement cushion layer;

[0054] (3) Lift the other end of the reinforcement pad back block by the lifting buckle on the other side, and move the reinforcement pad back block into a suitable position, flush with the foundation pit

[0055] (4) Further align the front-supported grouting steel pipe piles and the positioning holes reserved in the foundation pit.

[0056] (5) Connect the rear block to the front-supported grouting steel pipe piles and to other adjacent plates;

[0057] (6) Use special buckles to hoist the front block to the corresponding position and connect it to the front support grouting steel pipe pile.

[0058] (7) Connect the front block to other adjacent blocks;

[0059] (8) After the adjacent reinforcement cushion layers are installed, grouting is injected into the pouring pipes in the reinforcement cushion layers through the grouting ports to form an integral structure.

[0060] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An assembled front-support grouting steel pipe pile reinforcement cushion structure and a manufacturing method, characterized by: The structure of the reinforced cushion layer consists of a front block and a rear block, which are spliced around the grouting steel pipe piles. The rear block is close to one side of the edge of the foundation pit, and the front block is located on the other side of the front-supported grouting steel pipe piles.

2. The assembled front support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 1 is characterized in that: The front block and the rear block are both composed of a casting body, reinforcement, a casting pipe and corresponding grouting ports, positioning holes and lifting buckles.

3. The assembled front support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 1 is characterized in that: The mold for making the reinforcement cushion layer is a rectangle formed by four mutually perpendicular modules and has screw holes for fixing with adjacent modules.

4. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 3 is characterized in that: The module is composed of a plurality of units connected up and down, and the height of the cushion layer can be changed by changing the number of connected units.

5. The assembled front support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 3 is characterized in that: Holes for placing steel bars are left between the upper and lower molds, and reinforcement and grouting pipelines can be set as needed.

6. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 4 is characterized in that: The uppermost unit is provided with a slide rail, which can cooperate with the sliding platform to set the mold of the cushion layer characteristics. The characteristic mold includes a pipe mold, a positioning mold and a grouting port.

7. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 6 is characterized in that: The uppermost unit adopts different numbers of lifting clips, and can produce reinforcement cushion layers under different construction conditions without changing the mold body.

8. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 7 is characterized in that: The hoisting clips are composed of a row of annular clips fixed to the steel bars, which are placed in a slot between the top layer and the second layer for hoisting during construction.

9. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 1 is characterized in that: The pipe molds used for the front block and the rear block are a group that cooperate with each other, so that during construction, the gap between the front and rear blocks can surround the front-supported grouting steel pipe pile to form a stable whole.

10. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 1, characterized in that: The production method comprises: (1) Install each module from bottom to top and fix adjacent modules; (2) Arrange the reinforcement mesh, grouting pipes, lifting clips, pipe molds, grouting ports, and positioning molds in order from bottom to top; (3) Inject a certain amount of concrete based on the design plan, and after solidification, remove the following in the following order: pipe mold and positioning hole mold, surrounding mold, and casting pipe mold.

11. The assembled front-support grouting steel pipe pile reinforcement cushion structure and manufacturing method according to claim 1, characterized in that: The installation method includes: (1) Reserve positioning holes in the foundation pit and plan the placement location; (2) Use the special clip on one side to hoist the rear block from the gap of the front-supported grouting steel pipe pile to the specified height of the reinforcement cushion layer; (3) Lift the other end of the rear block of the reinforced cushion layer by using the lifting buckle on the other side to make the cushion layer flush with the foundation pit, further align the front-supported grouting steel pipe piles and the positioning holes reserved in the foundation pit, and then connect the rear block with the front-supported grouting steel pipe piles and connect it with other adjacent plates; (4) Hoist the front block to the corresponding position through a special buckle, connect it to the front support grouting steel pipe pile, and then connect it to other adjacent plates; (5) After the adjacent reinforcement cushion layers are installed, grouting is injected into the pouring pipes in the reinforcement cushion layers through the grouting ports to form an integral structure.

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