Method for manufacturing, mounting and constructing high-pier and large-span steel guide beam in mountainous area

Abstract

The invention discloses a mountainous area high-pier large-span steel guide beam manufacturing, installing and constructing method. A cantilever bracket, a guide beam assembly jig frame, a guide beam assembly, a beam lifting station, a lifting portal, a guide beam lifting transverse moving system and other structures are included. A cantilever bracket is arranged at the pier top position to serve as a guide beam and steel beam pushing platform; a guide beam assembly jig frame is arranged between pier columns, the guide beam assembly precision is ensured, a beam lifting station and a lifting portal frame structure are installed at the pier top position, two 50t lifting crown blocks on a lifting portal frame and a lifting shoulder pole beam of the beam lifting station are used for being connected with a lifting lug of a guide beam upper chord through a steel strand, and then the guide beam assembly jig frame and the lifting portal frame structure are assembled. The lifting portal frame and a hydraulic jack (the single telescopic stroke is 15 cm) on the beam lifting station are matched with an anchorage device and a clamping piece to be fixed, and four lifting points are synchronously lifted. After lifting in place, a lifting portal adopts two hydraulic continuous transverse moving jacks, a clamping groove is formed in the top of a portal distribution beam, meanwhile, a beam lifting station is provided with a transverse moving crown block system and transversely moves in place, a main chord member at the tail end of a guide beam is symmetrically placed on a temporary supporting pad on a cantilever bracket distribution beam, and the front end of the main chord member is placed on a temporary supporting pad of a pier top padstone.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge construction, and in particular to a method for manufacturing and installing a large-span steel guide beam for high piers in mountainous areas, including the construction of a cantilever bracket, a guide beam assembly cradle, guide beam assembly, a beam lifting station, a lifting gantry, guide beam lifting, and a transverse movement system. Background Art

[0002] During bridge jacking construction, guide beams are often installed at the front end of the main beam to facilitate jacking over the span and piers, while also reducing the jacking overturning moment, which is beneficial to smooth pier placement and anti-overturning stability. Traditional steel guide beam jacking over the span often utilizes an assembly site to assemble the guide beam and steel beam, and then jacking over the span and piers multiple times. This method requires a large assembly site, and the steel guide beam needs to be jacked over the span and piers multiple times. At the same time, the beam is dropped at a high height, posing a greater safety risk. To address the shortcomings of limited assembly space and a high beam drop height (6m), a cantilever bracket is installed at the pier top, and a guide beam assembly cradle is arranged between the pier columns. A beam lifting station and a lifting hanger are used to lift and laterally move the front and rear ends of the guide beam to the pier top and cantilever bracket, completing the guide beam jacking over the span and pier, improving construction efficiency and reducing safety risks.

[0003] The construction method has several main characteristics: 1. A guide beam installation cradle is set between the piers. The guide beam is lifted and moved horizontally to its full position, which can solve the problems caused by insufficient assembly space and steep terrain in mountainous areas.

[0004] 2. Using the lifting station and the lifting gantry to lift the guide beam as a whole, move it horizontally and install it in sections can speed up the efficiency of the guide beam crossing the pier and reduce the safety risks of high beam drop height. Summary of the Invention

[0005] In order to solve the above technical problems, the present invention provides a method for manufacturing, installing and constructing large-span steel guide beams for high piers in mountainous areas, which can solve the problems caused by insufficient assembly sites and steep terrain in mountainous areas. At the same time, it can speed up the efficiency of the guide beams crossing the piers and reduce the safety risks of high beam drop heights.

[0006] The present invention provides a method for manufacturing and installing a large-span steel guide beam for a high pier in a mountainous area, which is achieved by the following specific technical means: A method for manufacturing and installing a large-span steel guide beam for high piers in mountainous areas includes the design and construction of structures such as a cantilever bracket, a guide beam assembly cradle, guide beam assembly, a beam lifting station, a lifting gantry, guide beam lifting, and a transverse movement system.

[0007] Cantilever bracket installation: The cantilever bracket pier height is approximately 60m. After the entire bridge deck is assembled, the cantilever bracket is hoisted and installed using a crane. The distribution beam is constructed of HN600×200 steel, the upper chord of the assembly bracket is constructed of 2HN600×200 steel, the diagonal brace is constructed of 2HN600×200 steel, and the connection system is constructed of 2[16b steel. Walking jacks are installed on the distribution beam to push the steel guide beam segments.

[0008] Steel guide beam assembly: The standard span of a steel truss is 80m. To ensure the integral lifting and transverse movement of the steel guide beam onto the pier, the guide beam is designed to be 80m long. The steel guide beam is a truss structure, with 7m spacing across the bridge, consistent with the main bridge steel beams. The spacing between the guide beam truss nodes is 5m. Bolt connections are used between guide beam segments and between the steel guide beam and the upper and lower chords of the steel truss. The main chord of the steel guide beam is made of Q355B steel, while the remaining structure is made of Q235B steel. The steel guide beam is manufactured in sections at the factory, and the steel guide beam is assembled and connected after the on-site assembly cradle is fabricated.

[0009] Assembly cradle fabrication: measurement and layout were carried out below pier 10-11#, and the position of the cradle steel pipe column foundation was determined in combination with the terrain. Based on the on-site measured foundation bearing capacity (≥200kPa), a 1.5×1.5×0.5m C30 concrete independent foundation was selected for the cradle steel pipe column foundation. Φ426×6mm steel pipes were used for the columns, Φ219×6mm steel pipes were used for the connection system, and a 2HN400×200mm distribution beam was set on the top for assembly of steel guide beam segments.

[0010] Installation of 10# pier lifting beam station: 10# pier lifting beam station is anchored on the installed T-beam, the front end is supported on the T-beam by a pad beam, and the rear anchor is tied to the T-beam as a whole through the precision-rolled threaded steel bar and the lower anchor beam.

[0011] Installation of the lifting gantry for Pier 11#: A lifting gantry was installed at the top of Pier 11#. Eight Φ630×8mm steel pipe columns were installed on both sides of the left and right spandrel beams. 2HN900×300 steel section beams were used as distribution beams on the top of the columns. The distribution beams connected the trusses, which primarily utilized 2[28b steel as the main truss structure. I28b and 2[20b steel were used as transverse connections to connect the left and right trusses. A 50t overhead crane was installed on each side of the front end of the trusses, connecting them to the ground guide beams via Φ15.2mm steel strands.

[0012] Guide beam lifting and transverse movement design: Before lifting, four lifting lugs were installed at the front and rear fulcrums of the guide beam's upper chord. The front end was secured by two 50t lifting cranes on the 11# pier lifting gantry, connected to steel strands. The rear end was connected to the guide beam's front lifting lugs by the lifting slings at the lifting station. Pier 11#'s transverse movement employed two hydraulic continuous jacks, each with a 1.2m displacement. Holes were drilled at 1m intervals at the distribution beam locations on the lifting gantry. The trusses and distribution beams were connected using 2cm-thick PTFE slides, which were coated with butter. The 10# pier lifting station was equipped with a transverse movement crane system, capable of remote-controlled transverse movement via slide rails. Once transversely moved into position, one end was placed on the 10# pier assembly bracket, while the other end was connected to the 11# pier's top guide beam segment B, forming a single unit supported on the temporary support pads at the 11# pier.

[0013] The present invention has the following advantages: The present invention provides a method for manufacturing and installing a large-span steel guide beam for high piers in mountainous areas, which belongs to the field of bridge construction technology and includes the construction of a cantilever bracket, a guide beam assembly cradle, guide beam assembly, a beam lifting station, a lifting gantry, a guide beam lifting, and a transverse movement system. By setting a guide beam installation cradle between the 10-11# pier columns and lifting and transversely moving the guide beam as a whole, the effects of insufficient assembly space and the steep terrain in mountainous areas can be resolved. At the same time, by using the beam lifting station and the lifting gantry to lift, transversely move, and install the guide beam as a whole, the efficiency of the guide beam crossing the pier can be accelerated, and the safety risk of the high height of the dropped beam can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic diagram of the manufacturing and installation of a high-pier and large-span steel guide beam for mountainous areas according to the present invention; Figure 2 This is a schematic diagram showing the completion of the lifting and installation of a large-span steel guide beam for a high pier in a mountainous area according to the present invention; Figure 3-Figure 4 This is a layout diagram of a high pier cantilever bracket of the present invention; Figure 5 This is a layout diagram of the assembly of a steel guide beam in a mountainous area according to the present invention; Figure 6 This is a layout diagram of a beam lifting station according to the present invention; Figure 7-Figure 8 This is a layout diagram of a lifting mast according to the present invention.

[0015] Among them: cantilever bracket 1, guide beam assembly cradle 2, guide beam A segment assembly 3, guide beam B segment assembly 4, beam lifting station 5, lifting gantry 6, beam lifting station lifting and transverse movement system 7, lifting gantry lifting and transverse movement system 8, cantilever bracket upper chord 9, cantilever bracket diagonal rod 10, cantilever bracket embedded parts 11, cantilever bracket distribution beam 12, cantilever bracket connection system 13, guide beam assembly cradle connection system 14, guide beam assembly cradle column 15, guide beam assembly cradle distribution beam 16, guide beam assembly cradle column 17, beam lifting station lifting sling 18, beam lifting station rear anchor 19, beam lifting station front end pad beam 20, lifting gantry column 21, lifting gantry distribution beam 22, lifting gantry connection system 23, lifting gantry truss system 24, lifting gantry transverse movement jack 25, lifting gantry Teflon slide plate 26. DETAILED DESCRIPTION

[0016] The following will be combined with the Figures 1-8 The present invention is described in detail, and the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0017] The present invention provides a method for manufacturing and installing a large-span steel guide beam for high piers in mountainous areas, comprising the construction of a cantilever bracket 1, a guide beam assembly frame 2, a guide beam assembly 3, a beam lifting station 5, a lifting gantry 6, and guide beam lifting and lateral movement systems 7 and 8.

[0018] Cantilever bracket installation: The pier height at the cantilever bracket is approximately 60m. The cantilever bracket distribution beam 12 is constructed of HN600×200 steel, the assembly bracket upper chord 9 is constructed of 2HN600×200 steel, the diagonal beam 10 is constructed of 2HN600×200 steel, and the connection system 13 is constructed of 2[16b steel. After the entire bridge deck is assembled, the cantilever bracket is hoisted using a crane. A walking jack is placed on the distribution beam 12 to push the steel guide beam segments.

[0019] Steel guide beam assembly: The standard span of a steel truss is 80m. To ensure the integral lifting and transverse movement of the steel guide beam onto the pier, the guide beam 3 is designed to be 80m long. The steel guide beam 3 is a truss structure, with 7m spacing across the bridge, consistent with the main bridge's steel beams. The guide beam truss nodes are spaced 5m apart. Bolts are used to connect the guide beam segments and the upper and lower chords of the steel guide beam to the steel truss. The main chord of the steel guide beam is made of Q355B steel, while the remaining structure is constructed of Q235B steel. The steel guide beam is manufactured in sections at the factory, and the steel guide beam 3 is assembled and connected after the on-site assembly of the cradle 2.

[0020] Assembly cradle fabrication: measurement and layout were carried out below pier 10-11#, and the position of the cradle steel pipe column foundation 14 was determined in combination with the terrain. Based on the on-site measured foundation bearing capacity (≥200kPa), a 1.5×1.5×0.5m C30 concrete independent foundation was selected for the cradle steel pipe column foundation 14. Φ426×6mm steel pipe was used for the column 15, Φ219×6mm steel pipe was used for the connection system 17, and a 2HN400×200mm distribution beam 16 was set on the top for assembling the steel guide beam segments.

[0021] Installation of 10# pier lifting beam station: 10# pier lifting beam station 5 is anchored on the installed T-beam, and the front end is supported on the T-beam by a pad beam 20, and the rear anchor 19 is tied to the T-beam as a whole through the precision-rolled threaded steel bar and the lower anchor beam.

[0022] Installation of the lifting gantry of Pier 11#: A lifting gantry 6 is installed on the top of Pier 11#. A total of 8 Φ630×8mm steel pipe columns 21 are set up on both sides of the top of the left and right span beams. The top surface of the columns uses 2HN900×300 steel as the distribution beam 22. The distribution beam and the column head of the steel pipe column are connected by hf=10mm continuous fillet welds, and 200@200mm intermittent welding is used between the double-piece steel sections. The distribution beam connects the truss. The truss mainly uses 2[28b as the truss body 25. The transverse connection system 21 uses I28b and 2[20b to connect the left and right trusses. A 50t overhead crane is installed on the left and right sides of the front end of the truss, which is connected to the ground guide beam 3 through Φ15.2mm steel strands.

[0023] Guide beam lifting and transverse movement design 7 and 8: Before lifting, four lifting lugs are installed at the front and rear support points of the guide beam's upper chord. The front end is secured by two 50t lifting cranes 8 on the 11# pier lifting gantry 6, connected to steel strands. The rear end is connected to the guide beam's front lifting lugs by the lifting sling 18 of the lifting station. Pier 11# transverse movement 8 utilizes two hydraulic continuous jacks 25, each with a single-stroke displacement of 1.2m. Holes are drilled at 1m intervals at the distribution beam 22 of the lifting gantry. The truss and distribution beam are connected using 2cm-thick PTFE slides 26, which are coated with grease. The 10# pier lifting station is equipped with a transverse movement crane system 7, which can be remotely moved transversely via slide rails. Once in position, one end rests on the 10# pier assembly bracket 1, while the other end connects to the 11# pier top guide beam segment B 4, forming a single unit supported on the temporary support pads at the 11# pier top.

[0024] The present invention has the following advantages: The present invention provides a method for manufacturing and installing a large-span steel guide beam for high piers in mountainous areas, which belongs to the field of bridge construction technology, and includes the construction of a cantilever bracket 1, a guide beam assembly cradle 2, a guide beam assembly 3, a beam lifting station 5, a lifting portal 6, and guide beam lifting and transverse movement systems 7 and 8. By arranging a guide beam installation cradle 2 between piers 10 and 11#, and lifting and transverse movement 7 and 8 to lift the guide beam 3 as a whole into place, the effects of insufficient assembly space and the steep terrain in mountainous areas can be resolved. At the same time, by using the beam lifting station 5 and the lifting portal 6 to lift the guide beam as a whole, transverse movement 7 and 8, and install it in sections, the efficiency of the guide beam crossing the pier can be accelerated, and the safety risk of the high height of the dropped beam can be reduced.

[0025] The embodiments of the present invention only describe the application and installation of the present invention. Other similar construction methods, based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work, are within the scope of protection of the present invention.

[0026] The present invention has the following advantages: The present invention provides a method for manufacturing and installing a large-span steel guide beam for high piers in mountainous areas, which belongs to the field of bridge construction technology, and includes the construction of a cantilever bracket 1, a guide beam assembly cradle 2, a guide beam assembly 3, a beam lifting station 5, a lifting portal 6, a guide beam lifting and transverse movement system 7, 8, etc. By arranging a guide beam installation cradle 2 between the 10-11# pier columns, the guide beam 3 is lifted and moved as a whole into place by lifting and moving it laterally, which can solve the problems caused by insufficient assembly space and the steep terrain in mountainous areas. At the same time, the beam lifting station 5 and the lifting portal 6 are used to lift the guide beam as a whole, move it laterally 7, 8, and install it in sections, which can speed up the efficiency of the guide beam crossing the pier and reduce the safety risk of the high height of the dropped beam.

[0027] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for manufacturing and installing a high-span steel guide beam for a mountainous area, characterized in that: It includes the construction of a cantilever bracket (1), a guide beam assembly frame (2), a guide beam A segment assembly (3), a guide beam B segment assembly (4), a beam lifting station (5), a lifting gantry (6), a lifting and transverse movement system of the beam lifting station (7), and a lifting and transverse movement system of the lifting gantry (8); The steel guide beam manufacturing and installation construction method comprises: setting a cantilever bracket (1) at the pier top and cap beam position as a guide beam and steel beam assembly and jacking construction platform; setting a guide beam assembly cradle (2) between 10# and 11# piers for assembling (3) and welding the steel guide beam A; assembling the guide beam segment B (4) by using a tower crane at the 11# pier top position; installing a beam lifting station (5) and a guide beam lifting gantry (6) at the 10# pier T beam and the 11# pier top respectively, and using the beam lifting station and the lifting gantry lifting and transverse movement system (7) (8) to lift and transversely move the guide beam as a whole, and after transversely moving into place, one end is placed on the 10# pier cantilever bracket (1), and the other end is welded to the guide beam segment B (4).

2. The method for manufacturing and installing a high-span steel guide beam for a mountainous area according to claim 1 is characterized in that: Installation of cantilever bracket: The pier height of the cantilever bracket is about 60m. The cantilever bracket distribution beam (12) is made of HN600×200 steel, the assembly bracket upper chord (9) is made of 2HN600×200 steel, the diagonal rod (10) is made of 2HN600×200 steel, and the connection system (13) is made of 2[16b steel. After the cantilever bracket is assembled as a whole on the bridge deck, it is hoisted by a crane; a walking jack is arranged on the distribution beam (12) for jacking the steel guide beam segment; the cantilever bracket can be used as a guide beam and steel beam assembly and jacking platform, which can reduce the height of the dropped beam, reduce the investment in temporary brackets, and save costs.

3. The method for manufacturing and installing a high-span steel guide beam for a mountainous area according to claim 1 is characterized in that: Assembling of steel guide beams: The standard span of steel trusses is 80m. To ensure the overall lifting and transverse movement of the steel guide beams onto the piers, the design length of the guide beams (3) is 80m. The steel guide beams (3) are truss structures. The truss spacing in the transverse direction of the bridge is 7m, which is consistent with the steel beams of the main bridge. The guide beam truss node spacing is 5m. The guide beam segments and the upper and lower chords of the steel guide beams and steel trusses are all connected by bolts. The main chords of the steel guide beams are made of Q355B material, and the rest of the structure is made of Q235B steel. They are manufactured in pieces in the factory. After the assembly frame (2) is made on site, the steel guide beam A segments are assembled (3) and connected. The guide beam B segments (4) are assembled on the top of the 11# pier.

4. The method for manufacturing and installing a high-span steel guide beam for a mountainous area according to claim 3 is characterized in that: Assembly frame production: measurement and layout are carried out below pier 10-11#, and the position of the frame steel pipe column foundation (14) is determined in combination with the terrain. According to the actual foundation bearing capacity measured on site (≥200kPa), the frame steel pipe column foundation (14) is selected as a 1.5×1.5×0.5m C30 concrete independent foundation, the column (15) is made of Φ426×6mm steel pipe, the connection system (17) is made of Φ219×6mm steel pipe, and a 2HN400×200mm distribution beam (16) is set on the top for steel guide beam segment assembly; the steel guide beam segment A (3) is assembled on the assembly frame (2) to ensure assembly accuracy; Installation of 10# pier lifting beam station: 10# pier lifting beam station (5) is anchored on the installed T-beam, and the front end is supported on the T-beam by a pad beam (20), and the rear anchor (19) is tied to the T-beam as a whole through the finished rolled threaded steel bar and the lower anchor beam.

5. The method for manufacturing and installing a high-span steel guide beam for a mountainous area according to claim 1 is characterized in that: Installation of the lifting gantry of Pier 11#: A lifting gantry (6) is set up on the top of Pier 11#. A total of 8 Φ630×8mm steel pipe columns (21) are set up on both sides of the top of the left and right span beams. The top surface of the column uses 2HN900×300 steel as the distribution beam (22). The distribution beam and the column head of the steel pipe column are connected by hf=10mm continuous fillet welds, and 200@200mm intermittent welding is used between the double-piece steel. The distribution beam connects the truss. The truss mainly uses 2[28b as the truss body (25). The transverse connection system (21) uses I28b and 2[20b to connect the left and right trusses. A 50t overhead crane (8) is installed on the left and right sides of the front end of the truss, and is connected to the ground guide beam (3) through Φ15.2mm steel strands.

6. The method for manufacturing and installing a high-pier and large-span steel guide beam in a mountainous area according to claim 1 is characterized in that: Design of the guide beam lifting and transverse movement system (7) (8): Before lifting, a total of 4 lifting lugs are set at the front and rear support points of the guide beam upper chord. The front end is fixed by two 50t lifting cranes (8) on the 11# pier lifting gantry (6) after connecting the steel strands, and the rear end is connected to the guide beam front end lifting lug by the lifting sling (18) of the lifting beam station; 11# pier transverse movement (8) uses a total of 2 hydraulic continuous jacks (25), with a single-stroke displacement of 1.2m. Holes are opened at intervals of 1m at the distribution beam (22) of the lifting gantry. The truss and the distribution beam are connected by 2cm thick PTFE slide plates (26), and the surface is coated with butter; 10# pier lifting beam station is equipped with a transverse movement crane system (7), which can be remotely moved transversely by slide rails; after transverse movement into place, one end is placed on the 10# pier assembly bracket (1), and the other end is connected to the 11# pier top guide beam segment B (4) to form a whole and supported on the 11# pier top temporary support pad.

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