Process for manufacturing and assembling a large docking pontoon

Abstract

The application discloses a manufacturing and assembling process method of a large-scale berthing pontoon. The method is characterized in that, first, the top plate is in a lower state, the middle web plate, the outer web plate, the hollow web plate and the top plate are fully welded from the top, and the bottom plate is spot welded; then, the steel box unit is turned over, the top plate is in an upper state, and the bottom plate and the hollow web plate are fully welded from the top in the hollow web plate space, so that the problem of needing to weld from the top when welding the top plate bottom and the web plate and the side sealing plate top connecting part in the channel is solved, and the labor intensity of the welding operation from the top is avoided.

Description

Technical Field

[0001] This invention relates to a manufacturing and assembly process for a large berthing pontoon, belonging to the field of offshore floating platform technology. Background Technology

[0002] Mooring pontoons form floating platforms at sea, which can be used for purposes such as maritime cargo transportation and offshore operations. The pontoon hull requires the assembly of multiple prefabricated hull units, as detailed in Chinese Patent No. CN208802126U.

[0003] The existing technology for prefabricated box units, as seen in Chinese Patent No. CN217460217U, allows for welding between the bottom plate and top plate, and between the web plate and the bottom plate and top plate, within the channel. However, welding the connection between the bottom of the top plate and the web plate and the top of the side sealing plate within the channel requires looking upwards, which results in high labor intensity. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a manufacturing and assembly process for large berthing pontoons.

[0005] The present invention is achieved through the following technical solutions.

[0006] This invention provides a manufacturing and assembly process for a large berthing pontoon, comprising:

[0007] The steel box unit needs to be flipped over for top-view full welding to achieve the prefabrication process.

[0008] The manufacturing process includes:

[0009] The two top plates are first laid down and welded, and the T-shaped longitudinal ribs and angle steel are welded and fixed to the top plates.

[0010] The hollow partition in the middle is welded and fixed to the middle of the top plate. Angle steel and longitudinal web plate are welded and fixed on both sides of the hollow partition in the middle. Columns and round pipes are welded and fixed on the hollow partition in the middle.

[0011] Weld and fix the hollow partitions on both sides of the top plate. Weld and fix angle steel and round pipes on the hollow partitions on both sides. Weld and fix the outer web plates on both sides of the top plate. Weld and fix the outer web plates to the hollow partitions on both sides. Weld and fix the angle steel and T-shaped longitudinal ribs on the top of the three hollow partitions. At this time, the top full welding of the middle web plate, outer web plate, hollow partitions and top plate is completed.

[0012] The base plate is placed on top of the three hollow partitions and temporarily fixed by spot welding to form a steel box unit with three box holes in cross section. The steel box unit is turned over and the base plate is fully welded to the three hollow partitions, angle steel and T-shaped longitudinal ribs from the top view.

[0013] The manufacturing process also includes: transporting prefabricated steel box units to the dock site by vehicle, and assembling multiple steel box units to form a berthing pontoon.

[0014] The berthing pontoon is welded and fixedly installed with transversely distributed solid web partitions in the middle. Longitudinal angle steels on the outer perimeter of the hollow web partitions penetrate the solid web partitions. End sealing plates are welded and fixedly installed at both ends of the berthing pontoon. Waist plates are welded and fixedly installed in the middle of both the end sealing plates and the solid web partitions. The waist plates are welded and fixedly installed with vertically distributed angle steels at their upper and lower ends to the angle steels that penetrate the solid web partitions longitudinally. The solid web partitions separate the middle web plates and outer web plates between the steel box units.

[0015] The manufacturing process also includes: forming independent connecting spaces between the solid bulkheads inside the berthing pontoon and between the solid bulkheads and the end caps; pouring concrete into the connecting spaces; lowering the berthing pontoon to sea level; and installing counterweights inside the berthing pontoon to adjust the draft and water balance.

[0016] The buoy has draft gauge lines at the four corners of its exterior.

[0017] The top of the mooring pontoon has a towing cable point, a bollard, and a manhole, and a ladder is provided on the middle web plate below the manhole.

[0018] The joints of the top plate, bottom plate, and outer web of the steel box units are staggered.

[0019] The outer perimeter of the berthing pontoon has multiple fender structures.

[0020] The beneficial effects of this invention are as follows: First, with the top plate in the lower position, the middle web plate, outer web plate, hollow partition plate and top plate are fully welded from a top view, and the bottom plate is spot welded; then the steel box unit is flipped over, with the top plate in the upper position, and the bottom plate and hollow partition plate are fully welded from a top view within the hollow partition plate space. This solves the problem of having to look up when welding the connection between the bottom of the top plate and the web plate and the top of the side sealing plate in the channel, and avoids the labor intensity of looking up welding operations. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the berthing pontoon of the present invention;

[0022] Figure 2 This is a top view schematic diagram of the misaligned splicing joints of the top plate and outer web plate of the present invention;

[0023] Figure 3 This is a bottom view of the misaligned splicing joints of the outer web and bottom plate of the present invention.

[0024] Figure 4 This is a schematic diagram of the longitudinal distribution of the three steel box units of the present invention;

[0025] Figure 5 This is a structural schematic diagram of the top plate of the present invention in the lower state;

[0026] Figure 6 This is a structural schematic diagram of the present invention when the buoy is docked, showing the solid-body bulkhead;

[0027] Figure 7 This is a schematic diagram of the distribution of the solid-core partition and waist plate of the present invention;

[0028] Figure 8 This is a schematic diagram of the distribution of the solid-belly partition, hollow-belly partition, and waist plate of the present invention;

[0029] Figure 9 This is a schematic diagram of the distribution of the lug plate and the middle web plate of the present invention. Detailed Implementation

[0030] The technical solution of the present invention is further described below, but the scope of protection is not limited to what is described.

[0031] Reference manual attached Figures 1 to 9 As shown.

[0032] The present application discloses a manufacturing and assembly process for a large berthing pontoon, comprising two main steps: prefabrication of steel box units and assembly of the berthing pontoon.

[0033] The prefabrication steps for the steel box unit are as follows.

[0034] One steel box unit corresponds to two top plates 1, one bottom plate 2, two middle web plates 3, two outer web plates 4, and three hollow partitions 5 for material preparation.

[0035] The two top plates 1 are first laid down in the bottom position and then welded together. This can be understood as... Figure 4 Rotate from the top plate 1 position to Figure 5 With the top plate 1 at the bottom, the T-shaped longitudinal ribs 6 and angle steel 11 are welded and fixed to the top plate 1.

[0036] The hollow partition 5 in the middle is welded and fixed to the middle of the top plate 1. Angle steel 11 and longitudinal middle web plate 3 are welded and fixed on both sides of the hollow partition 5 in the middle. Column 7 and round pipe 8 are welded and fixed on the hollow partition 5 in the middle.

[0037] Weld and fix the hollow partition plates 5 on both sides of the top plate 1. Weld and fix angle steel 11 and round pipe 8 to the hollow partition plates 5 on both sides. Weld and fix the outer web plates 4 on both sides of the top plate 1. Weld and fix the outer web plates 4 to the hollow partition plates 5 on both sides. Weld and fix the angle steel 11 and T-shaped longitudinal ribs 6 on the top of the three hollow partition plates 5. At this time, the top plate 1 is fully welded from top view to the middle web plate 3, outer web plate 4, hollow partition plates 5, and top plate 1.

[0038] The base plate 2 is placed on top of the three hollow partition plates 5 and temporarily fixed by spot welding to form a steel box unit with a cross-section of three box holes. The steel box unit is then flipped over so that the top plate 1 is... Figure 5 Rotate to the following state Figure 4 In the top position, the bottom plate 2 is fully welded to the three hollow partitions 5, angle steel 11, and T-shaped longitudinal ribs 6 from a top view.

[0039] During the prefabrication of the steel box unit, with the top plate 1 in the lower position, the middle web plate 3, outer web plate 4, and hollow partition plate 5 are fully welded to the top plate 1 from a top-down view, and the bottom plate 2 is spot welded. The steel box unit is then flipped over, with the top plate 1 in the upper position, and the bottom plate 2 is fully welded to the hollow partition plate 5 from a top-down view within the space of the hollow partition plate 5. This solves the problem of having to weld from below when welding the connection between the bottom of the top plate and the web plate and the top of the side sealing plate in the passage, and avoids the labor intensity of welding from below.

[0040] The assembly steps for the berthing pontoon are as follows.

[0041] Prefabricated steel box units are transported by vehicle to the dock site. Multiple steel box units are assembled to form berthing pontoons. Figure 1 , Figure 6 The top plate 1, bottom plate 2, and outer web plate 4 of the steel box units are fixedly installed by bevel welding at the joints; at this time, transversely distributed solid web partitions 10 are welded and fixedly installed in the middle of the berthing pontoon, and longitudinal angle steel 11 on the outer periphery of the hollow web partitions 5 penetrate the solid web partitions 10, such as... Figures 7 to 8 End caps 12 are welded and fixed at both ends of the berthing pontoon. Waist plates 13 are welded and fixed to the middle of both the end caps 12 and the solid web partition 10. Vertically distributed angle steel 11 is welded and fixed to the waist plates 13, with its upper and lower ends welded to the angle steel 11 that longitudinally penetrates the solid web partition 10. (See...) Figures 6 to 8 Solid partition 10 separates the middle web plate 3 and outer web plate 4 between the steel box units. The bottom of the berthing pontoon is lifted by airbag inflation and pushed into the water by a forklift.

[0042] The solid-web bulkheads 10 within the mooring pontoon and the space between the solid-web bulkheads 10 and the end cap 12 form independent communicating spaces, such as... Figure 6 As shown, concrete is poured into the connected space, and the buoy is moored to the sea level. Counterweights are installed inside the buoy to adjust the draft and balance.

[0043] The outer web plate 4 at each of the four corners of the berthing pontoon has a draft gauge line 14 greater than 3m. Figure 4 The diagram shows a location where the draft gauge line is used to observe the draft depth after the buoy is launched into the sea.

[0044] The joints of the top plate 1, bottom plate 2, and outer web plate 4 of the steel box units are staggered. Figure 2 , Figure 3As shown, the top plate 1 of the previous steel box unit is welded to the top surface of the outer web plate 4 of the next steel box unit, and the bottom plate 2 of the next steel box unit is welded to the bottom surface of the outer web plate 4 of the previous steel box unit, so that the splicing seams of the top plate 1, the splicing seams of the outer web plate 4, and the splicing seams of the bottom plate 2 present a staggered joint structure.

[0045] The cross-section of the steel box unit is a three-hole structure, which requires stable support in the middle of the steel box unit. The existing support in the middle of the steel box unit is disclosed in Chinese Patent No. CN202295235U, which uses vertical longitudinal bulkhead columns to strengthen the support in the middle of the box. However, when subjected to local stress, the box cannot bear the stress evenly in different parts.

[0046] This application discloses a steel box unit for mooring pontoons, comprising:

[0047] The bottom plate 2 and the top plate 1 are provided. The bottom plate 2 has outer web plates 4 on both sides. The outer web plates 4 are welded and fixed to the top plate 1 and the bottom plate 2 respectively.

[0048] There are two spaced-apart intermediate webs 3 between the outer webs 4. The intermediate webs 3 are welded and fixed to the top plate 1 and the bottom plate 2 respectively.

[0049] Hollow partitions 5 are welded and fixedly installed between the middle web plates 3 and between the middle web plates 3 and the outer web plates 4. Round tubes 8 are welded and fixedly installed inside the hollow partitions 5. A column 7 is welded and fixedly installed in the middle of the hollow partition 5. T-shaped longitudinal ribs 6 are welded and fixedly installed above and below the column 7.

[0050] The hollow partitions 5 between the middle web plates 3 are hollow annular plates; the hollow partitions 5 between the middle web plate 3 and the outer web plate 4 are C-shaped hollow annular plates. See Figures 4 to 5 As shown.

[0051] Angle steels 11 are welded and fixedly installed at intervals on the outer periphery of the hollow partition 5. Multiple angle steels 11 transmit the forces borne by various parts of the box to the hollow partition 5, and then the forces are distributed through multiple angle steels 11.

[0052] The steel box of this application transmits and disperses the force it bears through three hollow partitions 5 and angle steels 11 spaced around the outer perimeter of the hollow partitions 5, thus solving the problem that the box cannot bear the force evenly when it is subjected to local stress.

[0053] After multiple steel box units are prefabricated, they are transported from the prefabrication plant to the dock, where they need to be hoisted and assembled. The existing box design, as seen in Chinese Patent No. CN207311773U, features lifting lugs on the top plate to meet hoisting requirements, which is unfavorable for transporting the steel box units through transport routes with limited height.

[0054] The present application discloses a lifting lug structure for mooring a pontoon, comprising:

[0055] A lifting lug plate 15 is fixed to the web plate 3. The lifting lug plate 15 has lifting holes for connecting to cables or hooks on cables. A cable passage hole 16 is provided on the top plate 1 above the lifting lug plate 15, allowing cables to enter. The lifting lug plate 15 is welded and fixed to the web plate 3 via a reinforcing plate 17. (See figure) Figure 9 , Figure 4 As shown.

[0056] A reinforcing seat 18 larger than the lug plate 15 is welded and fixed to the middle web plate 3 located on the back of the lug plate 15. The reinforcing seat 18 increases the deformation resistance of the back of the middle web plate 3.

[0057] The middle web plate 3 is welded and fixed with the top plate 1 and the bottom plate 2 on the upper and lower sides respectively. The outer web plate 4 is located on the outer side of the middle web plate 3. The outer web plate 4 is welded and fixed with the top plate 1 and the bottom plate 2 on the upper and lower sides respectively. The top plate 1, the bottom plate 2, the middle web plate 3, and the outer web plate 4 constitute a steel box unit with a three-hole structure.

[0058] The lifting lug 15 is located on the middle web 3 inside the space between the top plate 1 and the bottom plate 2. The middle web 3 does not occupy the height dimension of the steel box unit, so that the steel box unit can be manufactured to the maximum height limit of the transportation road conditions during prefabrication. This solves the problem that the lifting lug is on the top plate, which is not conducive to the transportation of the steel box unit through the limited transportation road conditions.

[0059] A manhole is provided on the top plate 1 near the cable hole 16. An openable cover plate 19 is installed on the top plate 1 at the manhole. A ladder 20 is provided on the middle web plate 3 below the manhole. Figure 4 As shown; when pouring concrete into the internal space of the steel box unit of the mooring pontoon, the concrete pump pipe extends into the manhole, and the internal gas is exhausted through the cable passage hole 16, so that the air containing dust in the mooring pontoon can be quickly discharged. After the concrete pouring is completed, the cable passage hole 16 is sealed and welded with a steel plate. Figure 1 Cable hole 16 is not shown in the diagram.

[0060] When berthing pontoons are moored to the dock, buffers need to be installed to prevent hard collisions between the pontoons and the dock. Existing technology (see Chinese patent application publication number CN119975707A) uses elastic marine ferries to provide cushioning to avoid collisions. However, when the sides of the pontoon have thin outer web plates, this can easily lead to localized deformation and indentation of the outer web plates due to stress.

[0061] This application discloses a fender structure for mooring pontoons, comprising:

[0062] Multiple steel box units constitute the berthing pontoon. A bracket is welded and fixedly installed on the outer web plate 4 of the steel box unit. A rubber body 26 is bonded and fixedly connected to the bracket. The rubber body 26 and the bracket form a fender structure on the outer web plate 4 of the berthing pontoon that provides elastic cushioning.

[0063] The bracket consists of vertical plates 22, longitudinal plates 23, and a mounting panel 21. Multiple vertical plates 22 and longitudinal plates 23 are welded and fixed perpendicularly and alternately. The multiple vertical plates 22 and longitudinal plates 23 are in multiple fixed contacts with the outer web plate 4. The mounting panel 21 is welded and fixed to the vertical plates 22 and longitudinal plates 23, and the rubber body 26 is fixed to the mounting panel 21. See [link / reference] Figure 4 , Figure 1 . Figure 1 Multiple fender structures are shown on the left side of the middle section. These fender structures are located on the outer periphery of the mooring pontoon and can be installed as needed.

[0064] The powered vessel is pulled by the towing cable connected to the towing cable point 25 of the berthing pontoon. When it approaches the dock, the mooring cable is used to bypass the mooring bollard 24 on the berthing pontoon and connect with the dock. When the rubber body 26 comes into contact with the dock, the collision force received by the rubber body 26 is distributed to the outer web plate 4 through the mounting panel 21 through multiple vertical plates 22 and multiple longitudinal plates 23, which solves the problem of local stress causing dent deformation of the outer web plate.

Claims

1. A manufacturing and assembly process for a large berthing pontoon, characterized in that, include: The steel box unit needs to be flipped over for top-view full welding to achieve the prefabrication process; The manufacturing process includes: The two top plates (1) are first laid in the bottom position and then welded. The T-shaped longitudinal ribs (6) and angle steel (11) are welded and fixed to the top plate (1). The hollow partition (5) in the middle is welded and fixed to the middle of the top plate (1). Angle steel (11) and longitudinal middle web plate (3) are welded and fixed on both sides of the hollow partition (5). Column (7) and round pipe (8) are welded and fixed on the hollow partition (5). Weld and fix the hollow partitions (5) on both sides of the top plate (1). Weld and fix the angle steel (11) and round pipe (8) on the hollow partitions (5) on both sides. Weld and fix the outer web plate (4) on both sides of the top plate (1). Weld and fix the outer web plate (4) to the hollow partitions (5) on both sides. Weld and fix the angle steel (11) and T-shaped longitudinal rib (6) on the top of the three hollow partitions (5). At this time, the top full welding of the middle web plate (3), outer web plate (4), hollow partitions (5) and top plate (1) is completed. The base plate (2) is placed on top of the three hollow partitions (5) and temporarily fixed by spot welding to form a steel box unit with three box holes in cross section. The steel box unit is turned over and the base plate (2) is fully welded to the three hollow partitions (5), angle steel (11), and T-shaped longitudinal rib (6) from a top view. The berthing pontoon is welded and fixedly installed with a horizontally distributed solid partition (10) in the middle. The longitudinal angle steel (11) on the outer periphery of the hollow partition (5) penetrates the solid partition (10). The berthing pontoon is welded and fixedly installed with end sealing plates (12) at both ends. The end sealing plates (12) and the solid partition (10) are both welded and fixedly installed with waist plates (13) in the middle. The waist plates (13) are welded and fixedly installed with the upper and lower ends of the vertically distributed angle steel (11) and the angle steel (11) that penetrates the solid partition (10) in the longitudinal direction. The solid partition (10) separates the middle web plate (3) and the outer web plate (4) between the steel box units.

2. The manufacturing and assembly process of the large berthing pontoon as described in claim 1, characterized in that, The manufacturing process also includes: transporting prefabricated steel box units to the dock site by vehicle, and assembling multiple steel box units to form a berthing pontoon.

3. The manufacturing and assembly process of the large berthing pontoon as described in claim 1, characterized in that: The manufacturing process also includes: forming an independent connecting space between the solid partitions (10) inside the mooring pontoon and between the solid partitions (10) and the end sealing plate (12); pouring concrete into the connecting space; lowering the mooring pontoon into the sea; and installing counterweights inside the mooring pontoon to adjust the draft and draft balance.

4. The manufacturing and assembly process of the large berthing pontoon as described in claim 1, characterized in that: The berthing pontoon has draft lines (14) at the four outer corners.

5. The manufacturing and assembly process of the large berthing pontoon as described in claim 1, characterized in that: The top of the mooring pontoon has a towing cable point (25), a bollard (24) and a manhole, and the middle web plate (3) below the manhole is equipped with a ladder (20).

6. The manufacturing and assembly process of the large berthing pontoon as described in claim 1, characterized in that: The joints of the top plate (1), bottom plate (2), and outer web plate (4) of the steel box units are staggered.

7. The manufacturing and assembly process of the large berthing pontoon as described in claim 2, characterized in that: The outer perimeter of the berthing pontoon has multiple fender structures.

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