Light assembly type high-performance concrete box culvert and manufacturing and mounting construction method thereof

Abstract

The invention relates to the technical field of highway engineering construction, in particular to a light assembly type high-performance concrete box-type culvert and a manufacturing and mounting construction method thereof, and aims to solve the problems that in the current building culvert manufacturing and forming process, due to the fact that the mode of overall pre-pouring and then transferring and mounting is generally adopted, time and labor are wasted in the manufacturing and transporting process of a large-span culvert, and construction efficiency is high. The number of divided prefabricated segments is large, and finally the bridge and culvert construction cost and efficiency are affected. The culvert is mainly composed of a cast-in-place bottom plate, prefabricated middle side walls and brackets, a prefabricated top plate, cast-in-place concrete and the like, the middle side walls and the top plate are intensively produced in a factory, the middle side walls are poured step by step, so that the middle side walls form an integral structure with supporting brackets, and then the prefabricated middle side walls and the prefabricated top plate are transported to a site to be rapidly installed. And the inter-plate grout stopping rubber strips are matched, concrete leakage during cast-in-place is avoided, the whole culvert is tensioned and leveled in combination with the horizontal adjusting screw rod at the middle side wall, and the transportation efficiency and the installation quality of the culvert are effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of highway engineering construction, and in particular to a light assembled high-performance concrete box culvert and a manufacturing and installation method thereof. Background Art

[0002] A culvert refers to a drainage channel built under the roadbed and below the road surface during highway construction in order to allow the highway to pass through the canal smoothly without hindering traffic. This structure allows water to flow through from under the highway and is used to drain floods across natural valleys and depressions, or to cross large and small roads as a traffic lane for people, livestock and vehicles, or as a canal for farmland irrigation. Culverts are mainly composed of components such as the tunnel body, foundation, end and wing walls. Culverts are based on the principle of communicating vessels and are usually built with materials such as bricks, stones, concrete and reinforced concrete. They generally have a small aperture and are shaped like tubes, boxes and arches. At present, the construction and installation process of highway culverts generally adopts the method of on-site casting. However, this type of culvert construction method is prone to the following problems: construction stage diseases caused by inadequate on-site concrete casting and curing; large amounts of cast steel bars and concrete are not well controlled, and the demand for supports, formwork and concrete curing facilities in the on-site casting construction process is large, resulting in low construction efficiency; on-site integral casting makes it difficult to effectively control the shrinkage, creep and hydration heat reaction of the culvert structure, which can easily lead to structural strength attenuation and secondary stress in specific parts, ultimately having a significant impact on the overall construction quality and production efficiency of highway bridges and culverts. Summary of the Invention

[0003] The present invention provides a lightweight assembled high-performance concrete box culvert and a manufacturing and installation method thereof to solve the problems existing in the above background.

[0004] In order to achieve the above object, the present invention adopts the following technical solutions: A lightweight assembled high-performance concrete box culvert includes symmetrically arranged cast-in-place bottom plates, multiple prefabricated middle walls are vertically fixed between one side of the cast-in-place bottom plates, multiple prefabricated side walls are vertically fixed on the other side of the cast-in-place bottom plates, multiple prefabricated top plates are horizontally arranged on the tops of the prefabricated side walls and the prefabricated middle walls, second cast-in-place concrete is filled between the prefabricated top plates, first cast-in-place concrete is filled between the prefabricated top plates and the prefabricated side walls, and leveling screws are movably provided horizontally between the prefabricated middle walls and the prefabricated side walls.

[0005] Furthermore, a first precast corbel is fixed between one side of the cast-in-place base plate, a second precast corbel is provided at the bottom of the second cast-in-place concrete, and the precast middle wall, the first precast corbel and the second precast corbel are precast as an integral structural arrangement.

[0006] Furthermore, a third precast corbel is fixedly provided on the other side of the cast-in-place base plate, a fourth precast corbel is provided on the bottom of the first cast-in-place concrete, and the fourth precast corbel, the third precast corbel and the precast side wall are all precast as an integral structural arrangement.

[0007] Furthermore, grout-stopping strips are adhered between the fourth prefabricated corbel and the prefabricated top plate, and between the prefabricated top plate and the second prefabricated corbel.

[0008] Furthermore, a plurality of adjusting connectors are detachably provided between the prefabricated middle walls and the prefabricated side walls, and the leveling screws are all threadedly connected to the adjusting connectors.

[0009] Furthermore, water-swellable rubber strips are bonded to the connection gaps between the prefabricated top plates and the prefabricated side walls.

[0010] A method for fabricating and installing a lightweight assembled high-performance concrete box culvert comprises the following steps: Step 1: First, make the prefabricated top plate in the factory, clean the formwork and mold, assemble them, tie the steel mesh, thread and tension the prestressed steel bundles, hoist the tied steel mesh into the mold, and finally cast the prefabricated top plate and maintain it. After checking that the production is qualified, release and demould.

[0011] Step 2, then proceed with the production of prefabricated middle wall and prefabricated side walls. First, cast the middle panels of the prefabricated middle wall and prefabricated side walls according to the production process of step 1. Then, use a crane or a crane to flip the middle panels of the prefabricated middle wall and prefabricated side walls 90 degrees, and place them upright on the formwork for the secondary casting. Then, the molds of the first prefabricated corbel, the second prefabricated corbel, the third prefabricated corbel and the fourth prefabricated corbel are positioned and installed on the prefabricated middle wall and prefabricated side walls through the sleeves on the middle panels of the prefabricated middle wall and prefabricated side walls respectively, and the reinforcing steel bars and the connecting steel bars are tied. Then, the first prefabricated corbel, the second prefabricated corbel, the third prefabricated corbel and the fourth prefabricated corbel are cast, so that the prefabricated middle wall, the first prefabricated corbel and the second prefabricated corbel constitute the overall installation structure, and the prefabricated side walls, the third prefabricated corbel and the fourth prefabricated corbel constitute the overall installation structure. Then, the prepared prefabricated side walls and prefabricated middle walls are covered with a film for maintenance.

[0012] Step 3: dismantle the molds of the first prefabricated corbel, the second prefabricated corbel, the third prefabricated corbel and the fourth prefabricated corbel, and transport the prefabricated top plate, prefabricated side wall and prefabricated middle wall to the construction site for installation.

[0013] Step 4: During installation, first install the integral components of the prefabricated side walls and prefabricated middle walls. The operator then rotates and adjusts the leveling screws to make the adjacent prefabricated side walls and prefabricated middle walls flush as a whole and checks whether the installation dimensions are qualified. Then, the cast-in-place base plate 1 is poured.

[0014] Step 5. Install the stop strip in the reserved gap between the prefabricated top plate and the second prefabricated corbel and the fourth prefabricated corbel, and paste the water-expanding rubber strip in the single-sided connection gap between the prefabricated top plates and the prefabricated side walls. Then, erect the prefabricated top plate, perform waterproofing on all joints, and finally pour the first cast-in-place concrete and the second cast-in-place concrete.

[0015] The present invention has the following beneficial effects: The present invention provides a lightweight assembled high-performance concrete box culvert and its manufacturing and installation method, which intensively produces components such as middle walls, side walls and top plates in a factory, and casts the middle walls and side walls in steps, so that the middle side walls form an integral structure with supporting corbels, and then the prefabricated middle side walls and top plates are transported to the construction site for rapid installation. At the same time, matching grouting strips between the plates are used to avoid leakage of concrete during casting. Combined with the horizontal adjustment screws at the middle side walls, the overall culvert is tightened and leveled, effectively ensuring the overall installation quality and efficiency of the culvert, and solving the problem that in the current preparation and forming process of large-span and large-volume culverts, the manufacturing and transportation process of the culvert is time-consuming and labor-intensive, and the hoisting risk is high and the efficiency is low, which ultimately affects the quality of bridge and culvert construction.

[0016] The present invention carries out intensive factory production of the top plate, side walls and middle walls of the culvert. At the same time, the side walls are cast in sections to form a corbel support structure, which effectively disperses the stress concentration effect of the box culvert nodes, optimizes the overall stress of the structure, and ensures the support stability of the culvert side walls and middle walls during on-site installation, effectively improving the overall manufacturing and installation efficiency and quality of the culvert.

[0017] The side walls, middle walls and top plates of the present invention are all bonded with grout-stopping strips, thereby effectively avoiding leakage of concrete during on-site concrete pouring, thereby ensuring the overall stability and strength of the culvert pouring connection. At the same time, water-expanding rubber strips are used at the joints between the culvert top plate and the side walls for bonding and sealing, effectively preventing the influence of fill seepage on the culvert during the use of the culvert.

[0018] In the present invention, by rotating the leveling screws provided on the side walls and the side of the middle wall, the horizontal adjustment screws can effectively tighten and level the entire culvert adjacent to the culvert, thereby greatly ensuring the flatness and integrity of the continuous installation of the culvert and improving the overall installation and construction quality of the culvert. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the structural connection of the fourth prefabricated corbel of the present invention.

[0021] Figure 3 This is a schematic diagram of the structural connection of the second prefabricated corbel of the present invention.

[0022] Figure 4 This is a schematic diagram of the structural arrangement of the leveling screw rod of the present invention.

[0023] The meanings of the reference numerals are as follows: 1. Cast-in-place base plate; 2. First precast corbel; 3. Precast middle wall; 4. Second precast corbel; 5. Third precast corbel; 6. Precast side wall; 7. Fourth precast corbel; 8. Precast top plate; 9. Stop grout strip; 10. First cast-in-place concrete; 11. Second cast-in-place concrete; 12. Water-expanding rubber strip; 13. Adjusting connector; 14. Leveling screw. DETAILED DESCRIPTION

[0024] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0025] like Figure 1-4 As shown, a lightweight assembled high-performance concrete box culvert includes a symmetrically arranged cast-in-situ bottom plate 1, a group of prefabricated middle walls 3 are vertically fixed between one side of the cast-in-situ bottom plate 1, and a group of prefabricated side walls 6 are vertically fixed on the other side of the cast-in-situ bottom plate 1. Two groups of prefabricated top plates 8 are horizontally arranged on the top of the prefabricated side walls 6 and the prefabricated middle walls 3. A second cast-in-situ concrete 11 is filled between the prefabricated top plates 8, and a first cast-in-situ concrete 10 is filled between the prefabricated top plates 8 and the prefabricated side walls 6. Leveling screws 14 are also movably provided horizontally between the prefabricated middle walls 3 and the prefabricated side walls 6.

[0026] A first precast corbel 2 is fixed between one side of the cast-in-place base plate 1, a second precast corbel 4 is provided at the bottom of the second cast-in-place concrete 11, and the precast middle wall 3, the first precast corbel 2 and the second precast corbel 4 are precast as an integral structural arrangement.

[0027] A third precast corbel 5 is fixedly provided on the other side of the cast-in-place base plate 1, and a fourth precast corbel 7 is provided at the bottom of the first cast-in-place concrete 10. The fourth precast corbel 7, the third precast corbel 5 and the precast side wall 6 are all precast as an integral structural arrangement.

[0028] Grout-stopping strips 9 are adhered between the fourth prefabricated corbel 7 and the prefabricated top plate 8 , and between the prefabricated top plate 8 and the second prefabricated corbel 4 .

[0029] A plurality of adjusting connectors 13 are bolted between the prefabricated middle walls 3 and the prefabricated side walls 6 , and the leveling screws 14 are threadedly connected to the adjusting connectors 13 .

[0030] Water-swellable rubber strips 12 are bonded to the connecting gaps between the prefabricated top plates 8 and the prefabricated side walls 6 .

[0031] Specifically, when making and installing a lightweight assembled high-performance concrete box culvert, the following steps are included: Step 1: First, make the prefabricated top plate 8 in the factory, clean the formwork and the mold, assemble them, tie the steel mesh, thread and tension the prestressed steel strands, hoist the tied steel mesh into the mold, and finally cast the prefabricated top plate 8 and maintain it. After checking that the production is qualified, release and demould; Step 2: Then, make the prefabricated middle wall 3 and prefabricated side wall 6. First, cast the middle plate of the prefabricated middle wall 3 and prefabricated side wall 6 according to the production process of step 1, and then flip the middle plate of the prefabricated middle wall 3 and prefabricated side wall 6 by crane or crane. 90 degrees, and place it upright on the secondary casting mold platform, and then the molds of the first prefabricated corbel 2, the second prefabricated corbel 4, the third prefabricated corbel 5 and the fourth prefabricated corbel 7 are respectively positioned and installed on the prefabricated middle wall 3 and the prefabricated side wall 6 through the sleeves on the middle plate of the prefabricated middle wall 3 and the prefabricated side wall 6, and the reinforcing steel bars and the connecting steel bars are tied, and then the first prefabricated corbel 2, the second prefabricated corbel 4, the third prefabricated corbel 5 and the fourth prefabricated corbel 7 are cast, so that the prefabricated middle wall 3, the first prefabricated corbel 2 and the second prefabricated corbel 4 form an installation integral structure, and the prefabricated The side wall 6, the third prefabricated corbel 5 and the fourth prefabricated corbel 7 constitute the overall structure of the installation, and then the prepared prefabricated side wall 6 and the prefabricated middle wall 3 are covered with a film for maintenance; Step 3, then remove the molds of the first prefabricated corbel 2, the second prefabricated corbel 4, the third prefabricated corbel 5 and the fourth prefabricated corbel 7, and transport the prefabricated prefabricated top plate 8, the prefabricated side wall 6 and the prefabricated middle wall 3 to the construction site for installation; Step 4, during installation, first install the overall components of the prefabricated side wall 6 and the prefabricated middle wall 3, and then the operator adjusts the leveling screw 14 by rotating it to make the corresponding The adjacent prefabricated side walls 6 and prefabricated middle walls 3 are in a flush state as a whole and the installation dimensions are checked to be qualified, and then the cast-in-place bottom plate 1 is poured; step 5, the slurry-stop strip 9 is added to the reserved gap between the prefabricated top plate 8 and the second prefabricated corbel 4 and the fourth prefabricated corbel 7, and the water-swelling rubber strip 12 is pasted on the single-sided connection gap between the prefabricated top plates 8 and the prefabricated side walls 6, and then the prefabricated top plate 8 is erected, and waterproofing is performed on all joints, and finally the first cast-in-place concrete 10 and the second cast-in-place concrete 11 are poured.

Claims

1. A lightweight assembled high-performance concrete box culvert, characterized by: The invention comprises a symmetrically arranged cast-in-situ bottom plate (1), a plurality of prefabricated middle walls (3) are vertically fixed between one side of the cast-in-situ bottom plate (1), a plurality of prefabricated side walls (6) are vertically fixed on the other side of the cast-in-situ bottom plate (1), a plurality of prefabricated top plates (8) are horizontally arranged on the tops of the prefabricated side walls (6) and the prefabricated middle walls (3), a second cast-in-situ concrete (11) is filled between the prefabricated top plates (8), a first cast-in-situ concrete (10) is filled between the prefabricated top plates (8) and the prefabricated side walls (6), and a leveling screw (14) is movably provided horizontally between the prefabricated middle walls (3) and the prefabricated side walls (6).

2. A lightweight assembled high-performance concrete box culvert according to claim 1, characterized in that: A first prefabricated corbel (2) is fixedly provided between one side of the cast-in-situ base plate (1), a second prefabricated corbel (4) is provided at the bottom of the second cast-in-situ concrete (11), and the prefabricated middle wall (3), the first prefabricated corbel (2) and the second prefabricated corbel (4) are prefabricated as an integral structural arrangement.

3. A lightweight assembled high-performance concrete box culvert according to claim 2, characterized in that: A third prefabricated corbel (5) is fixedly provided on the other side of the cast-in-situ bottom plate (1), a fourth prefabricated corbel (7) is provided on the bottom of the first cast-in-situ concrete (10), and the fourth prefabricated corbel (7), the third prefabricated corbel (5) and the prefabricated side wall (6) are all prefabricated as an integral structural arrangement.

4. The lightweight assembled high-performance concrete box culvert according to claim 3 is characterized by: A stop glue strip (9) is bonded between the fourth prefabricated corbel (7) and the prefabricated top plate (8), and between the prefabricated top plate (8) and the second prefabricated corbel (4).

5. The lightweight assembled high-performance concrete box culvert according to claim 2 is characterized by: A plurality of adjustment connectors (13) are detachably provided between the prefabricated middle walls (3) and the prefabricated side walls (6), and the leveling screws (14) are all threadedly connected to the adjustment connectors (13).

6. The lightweight assembled high-performance concrete box culvert according to claim 4 is characterized by: Water-swellable rubber strips (12) are bonded to the connecting gaps between the prefabricated top plates (8) and the prefabricated side walls (6).

7. Also included is a method for manufacturing and installing a lightweight assembled high-performance concrete box culvert, characterized in that: The following steps are involved: Step 1: First, the prefabricated top plate (8) is made in the factory, the mold platform and the mold are cleaned, and then they are assembled, and then the steel mesh is tied and the prestressed steel bundle is stretched, and the tied steel mesh is hoisted into the mold, and finally the prefabricated top plate (8) is cast and maintained, and after the production is checked to be qualified, the prefabricated top plate is stretched and demoulded; Step 2: The prefabricated middle wall (3) and the prefabricated side wall (6) are then produced. First, the middle panels of the prefabricated middle wall (3) and the prefabricated side wall (6) are cast according to the production process of step 1. Then, the middle panels of the prefabricated middle wall (3) and the prefabricated side wall (6) are turned 90 degrees by a crane or a driving crane, and are placed upright on the secondary casting mold platform. Then, the molds of the first prefabricated corbel (2), the second prefabricated corbel (4), the third prefabricated corbel (5) and the fourth prefabricated corbel (7) are respectively passed through the molds on the middle panels of the prefabricated middle wall (3) and the prefabricated side wall (6). The sleeve is positioned and installed on the prefabricated middle wall (3) and the prefabricated side wall (6), and the reinforcing steel bars and the connecting steel bars are tied, and then the first prefabricated corbel (2), the second prefabricated corbel (4), the third prefabricated corbel (5) and the fourth prefabricated corbel (7) are cast, so that the prefabricated middle wall (3), the first prefabricated corbel (2) and the second prefabricated corbel (4) constitute the overall installation structure, and the prefabricated side wall (6), the third prefabricated corbel (5) and the fourth prefabricated corbel (7) constitute the overall installation structure, and then the prepared prefabricated side wall (6) and the prefabricated middle wall (3) are covered with a film for maintenance; Step 3, dismantling the molds of the first prefabricated corbel (2), the second prefabricated corbel (4), the third prefabricated corbel (5) and the fourth prefabricated corbel (7), and transporting the prefabricated top plate (8), the prefabricated side wall (6) and the prefabricated middle wall (3) to the construction site for installation; Step 4: During installation, the prefabricated side walls (6) and the prefabricated middle wall (3) are first installed as a whole. The operator then rotates and adjusts the leveling screw (14) to make the adjacent prefabricated side walls (6) and the prefabricated middle wall (3) as a whole in a level state and checks whether the installation dimensions are qualified. Then, the cast-in-place base plate 1 is poured; Step 5: Install the stop glue strip (9) in the reserved gap between the prefabricated top plate (8) and the second prefabricated corbel (4) and the fourth prefabricated corbel (7), and paste the water-expandable rubber strip (12) in the single-side connection gap between the prefabricated top plates (8) and the prefabricated side walls (6). Then, erect the prefabricated top plate (8), perform waterproofing treatment on all joints, and finally pour the first cast-in-place concrete (10) and the second cast-in-place concrete (11).

Images