Core-pulling-free creeping formwork for cast-in-place construction of large-size caisson offshore wet dock

Abstract

The invention discloses a core-pulling-free creeping formwork for cast-in-place construction of a large-size caisson offshore wet dock, and relates to the technical field of port and ocean water conservancy projects, the core-pulling-free creeping formwork comprises a radial sliding table, a main hydraulic cylinder, a frame back ridge and a plurality of cambered surface formworks, one end of a supporting main hydraulic cylinder and the bottom end of a frame back ridge are hinged to a radial connecting line of the top face of the radial sliding table. The other end of the main hydraulic cylinder is hinged to the top end of the supporting frame back edge. The two ends of the frame back edge are adjusted in an arc length mode and axially adjusted in a staggered mode to support the cambered surface formwork. The contact faces of every two adjacent cambered surface formworks are made into sliding inclined faces which are symmetrical with the center of the creeping formwork as the original point, and the pouring arc length of the single creeping formwork is adjusted through the axial dislocation difference value of every two adjacent cambered surface formworks. According to the template, the pouring arc length of a single template can be adjusted in the pouring construction of the ultra-large hollow cone caisson, so that stepless adjustment of the inner diameter and the outer diameter of a circular ring of a circular pouring area defined by multiple templates is realized.

Description

Technical Field

[0001] This invention relates to the field of port and marine water conservancy engineering technology, and in particular to a core-free climbing formwork for the on-site construction of large-volume caissons in offshore wet docks. Background Technology

[0002] In port and marine engineering construction, large caissons are widely used as an important basic structure. Traditionally, large caissons are prefabricated in dry docks and then floated and sunk. However, this method is limited by the size, cost, and geographical location of the dry dock. Offshore wet dock casting technology, on the other hand, directly constructs a temporary cofferdam (wet dock) in a selected area at sea and casts the caissons within it, effectively overcoming the above-mentioned shortcomings.

[0003] However, the offshore wet dock environment is harsh (high salt spray, high humidity, and large waves), and the caissons are enormous, often designed as hollow cones with variable cross-sections to save concrete and adapt to the stress distribution of the foundation. This places extremely high demands on the core equipment for cast-in-place construction—the formwork system: firstly, the formwork must have climbing capabilities for layered pouring; secondly, the curvature and arc length of the formwork must be flexibly adjustable to adapt to changes in the caisson's cone angle to accommodate diameter variations at different elevations; and thirdly, in a wet dock environment lacking large onshore lifting equipment, the adjustment of the formwork must be convenient, precise, and reliable.

[0004] Existing climbing formwork technology is mostly used for walls with vertical or fixed curvature, making it difficult to adapt to construction with tapered surfaces and varying diameters. If piecemeal formwork is used, problems such as low construction efficiency, difficulty in controlling the alignment, poor sealing leading to grout leakage arise, seriously affecting the casting quality, construction safety, and schedule of the caisson. Therefore, there is an urgent need for a dedicated formwork system that integrates climbing, precise arc length adjustment, and tapered surface self-adaptation functions. Summary of the Invention

[0005] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, one object of the present invention is to provide a core-free climbing formwork for the on-site construction of large-volume caissons in offshore wet docks. This formwork can adjust the casting arc length of a single formwork during the casting construction of ultra-large hollow conical caissons, thereby achieving stepless adjustment of the inner and outer diameters of the annular casting area formed by multiple formworks.

[0006] To address this, the present invention proposes a core-free climbing formwork for the in-situ casting construction of large-volume caissons in offshore wet docks. The formwork includes a climbing platform arranged circumferentially on the inner and outer circumferential surfaces of a hollow conical caisson. The climbing formwork also includes a radial slide, a main hydraulic cylinder, a frame back rib, and multiple curved formwork panels. The radial slide slides horizontally and overlaps the construction surface of the climbing formwork platform. One end of the main hydraulic cylinder and the bottom end of the frame back rib are hinged along the radial line connecting the top surfaces of the radial slides. The other end of the main hydraulic cylinder is hinged to support the top end of the frame back rib. The two ends of the frame back rib are adjusted in arc length and axial displacement to support the curved formwork panels. The contact surface of two adjacent curved formwork panels is made into a sliding inclined plane symmetrical about the center of the climbing formwork panel. The casting arc length of a single climbing formwork panel is adjusted by the axial displacement difference between two adjacent curved formwork panels.

[0007] Preferably, the frame back rib includes an axial connecting rod, a connecting rod angle positioning plate, and a set of upper and lower arc length adjustment beams; multiple axial connecting rods are fixedly connected between the arc length adjustment beams, and the connecting rod angle positioning plate is radially fixed by the multiple axial connecting rods; the power output end of the main hydraulic cylinder is hinged on the connecting rod angle positioning plate; the two ends of the arc length adjustment beam are respectively adjusted in arc length and axially offset to support the two arc surface templates.

[0008] Preferably, the arc length adjustment beam includes an arc-shaped square steel pipe fixedly connected to both ends of the axial connecting rod, and an arc-shaped square steel column slidably and telescopically inserted into the two arc ends of the arc-shaped square steel pipe; the free ends of the arc-shaped square steel columns are radially penetrated and threadedly fixedly connected to radial screws, and the free ends of the radial screws are axially slidably adjusted to hang the arc surface template.

[0009] Preferably, multiple axial guide rails are fixed on the side of the curved template facing the climbing formwork platform, and the free end of the radial screw is tensioned and fixed in the axial guide rail.

[0010] Preferably, the two ends of the arc-shaped square steel tube are axially connected with pins. The middle section of the pins extends into the interior of the arc-shaped square steel tube and is inserted and positioned on the arc-shaped square steel column to fix the arc-shaped square steel tube and the arc-shaped square steel columns at both ends in the arc length direction.

[0011] Preferably, the free end of the radial screw extends into the axial guide rail and is threadedly connected to a radial lock nut. The end face of the radial lock nut abuts against the inner wall of the axial guide rail to lock the free end of the radial screw axially and radially inside the axial guide rail.

[0012] The advantages and technical effects of this invention are as follows:

[0013] 1. Beneficial effects of the overall system: The present invention integrates the conical surface adaptation functions of climbing, radial movement, and arc length adjustment, successfully solving the technical problem of the arc surface formwork for in-situ casting of large-volume conical caissons in the complex environment of a marine wet dock. The entire system has sufficient rigidity and good stability, can effectively resist the lateral pressure of concrete and the sea wind load, ensure accurate casting shape and smooth surface, and greatly improve the construction quality, efficiency, and safety.

[0014] 2. Function of the radial sliding table: The radial sliding table is the basis for the radial displacement adjustment of the entire arc surface formwork system. Its design of horizontally radially sliding and lapping on the climbing formwork platform enables the entire set of frame back ribs and arc surface formwork to move as a whole along the radius direction of the caisson. This function allows the same set of arc surface formwork to be fed radially for casting or retracted for demoulding as a whole, and at the same time, it initially adapts to the continuously changing diameter of the caisson at different casting heights (the casting of variable cross-section cones such as hourglass shape can also be achieved), laying a foundation for the subsequent fine adjustment of the arc length.

[0015] 3. Function of the main hydraulic cylinder and the hinge point: The main hydraulic cylinder and its stable hinge support system formed by the radial sliding table and the frame back ribs, which enclose a triangle, are the core power and execution mechanism for realizing the angle adjustment of the arc surface formwork. By controlling the extension and retraction of the main hydraulic cylinder, the frame back ribs can be pushed to rotate around the hinge point at its bottom, thereby changing its pitch angle. This action directly adjusts the inclination angle of the arc surface formwork connected to both ends of the frame back ribs, enabling it to precisely fit the designed taper of the caisson to ensure the forming accuracy of the conical structure.

[0016] 4. Function of the frame back ribs: The frame back ribs (composed of axial connecting rods, connecting rod angle positioning plates, and arc length adjustment beams) are the back "skeleton" of the arc surface formwork. The axial connecting rods, connecting rod angle positioning plates, and the arc length adjustment beams fixed at both ends of the axial connecting rods form a "day" - shaped structure, effectively transmitting and distributing the thrust of the main hydraulic cylinder to the entire frame, ensuring the overall stiffness of the arc surface formwork under the huge concrete pressure to avoid deformation of the arc surface formwork. The arc length adjustment beam, as the extension arm at the arc end of this skeleton, is directly responsible for carrying and adjusting the circumferential position of adjacent arc surface formworks.

[0017] 5. Function of the arc length adjustment beam: The arc length adjustment beam (composed of arc-shaped square steel pipes and arc-shaped square steel columns) is the key component for realizing stepless adjustment of the arc length. By adjusting the protruding length of the arc-shaped square steel columns at both arc ends of the beam, the unfolded arc length of the entire arc length adjustment beam can be changed. This design enables the covering arc length of the arc surface formwork to be flexibly and precisely adjusted to perfectly match the new casting perimeter requirements determined by the radial movement and angle adjustment, achieving the universality of "one set of arc surface formwork, multiple diameters", greatly improving the equipment utilization rate and economy.

[0018] 6. Function of the curved template and sliding ramp: Adjacent curved templates slide together via their contacting sliding ramps. When adjusting the arc length causes axial misalignment between the two curved templates, these symmetrical ramps will slide against each other. The misalignment is converted into an increase or decrease in the arc length covered by the curved template. This structure converts linear axial displacement into precise arc length changes. The adjustment process is smooth, continuous, and self-locking, ensuring a tight fit at the joint and effectively preventing grout leakage.

[0019] 7. Functions of the Radial Screw and Axial Guide Rail: The radial screw and axial guide rail form the axial misalignment positioning support mechanism of the curved template. Screwing the radial screw in or out allows for fine adjustment of the radial position of the curved template, ensuring that the working surface of the template is on the designed theoretical curved surface. Simultaneously, the radial screw can slide along the axial guide rail, allowing for axial displacement adjustment of a single curved template section, which is the basis for achieving the aforementioned inclined sliding adjustment (i.e., arc length adjustment). This system achieves precise control over the position of each curved template section.

[0020] 8. Functions of the pin and radial lock nut: The pin provides a rigid mechanical lock for the arc length adjustment beam. Inserted after adjustment, it firmly fixes the arc-shaped square steel column and arc-shaped square steel pipe, bearing the enormous shear force and bending moment generated during concrete pouring, ensuring the arc length parameter remains stable during construction. The radial lock nut is used to lock the radial screw. Tightening the lock nut causes its end face to firmly abut against the inner wall of the axial guide rail, thus constraining and fixing the radial screw in both the radial and axial directions, ultimately locking the arc template firmly in the preset position, ensuring the overall rigidity and stability of the system. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the construction location for the present invention;

[0023] Figure 2 This is a three-dimensional structural diagram of the present invention (arc-shaped template in a non-misaligned posture, outer arc template structure).

[0024] Figure 3 This is a three-dimensional structural diagram of the present invention (misaligned posture of the arc template, outer arc template structure).

[0025] Figure 4 This is a radial side view of the present invention (arc template in non-misaligned posture, outer arc template structure, main hydraulic cylinder not shown).

[0026] Figure 5 This is a tangential side view (outer arc template structure) of the present invention.

[0027] Figure 6 This is an axial sectional view of the present invention (showing the cross-sectional structure of the arc length adjusting beam and the axial guide rail).

[0028] Figure 7 This is a multi-pose tangential side view of the present invention (the casting arc length gradually decreases from bottom to top, and the main hydraulic cylinder is not shown).

[0029] In the diagram: 1-Climbing formwork template; 2-Hollow conical caisson; 3-Climbing formwork platform; 4-Radial slide; 5-Sliding inclined plane; 6-Curved formwork template; 7-Axial guide rail; 8-Radial screw; 9-Curved square steel column; 10-Curved square steel pipe; 11-Pin rod; 12-Connecting rod angle positioning plate; 13-Axial connecting rod; 14-Radial lock nut; 15-Main hydraulic cylinder; 16-Arch length adjusting beam. Detailed Implementation

[0030] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0031] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0032] The present invention will now be described in further detail with reference to the accompanying drawings.

[0033] like Figure 1-7As shown, the present invention discloses a core-free climbing formwork 1 for cast-in-place construction of a large-volume caisson in a wet dock, comprising a climbing formwork platform 3, which is circumferentially arranged on the inner and outer circumferential surfaces of the hollow conical caisson 2. The climbing formwork also includes a radial slide 4, a main hydraulic cylinder 15, a frame back rib, and multiple arc-shaped formwork panels 6. The radial slide slid horizontally on the construction surface of the climbing formwork platform. One end of the main hydraulic cylinder and the bottom end of the frame back rib are respectively hinged along the radial line connecting the top surface of the radial slide 4. The other end of the main hydraulic cylinder is hinged to support the top end of the frame back rib. The two ends of the frame back rib are respectively adjusted in arc length and axial offset to support the arc-shaped formwork panels. The contact surface of two adjacent arc-shaped formwork panels is made into a sliding inclined surface 5 symmetrical about the center of the climbing formwork panel. The casting arc length of a single climbing formwork panel is adjusted by the axial offset difference between two adjacent arc-shaped formwork panels.

[0034] Preferably, the frame back rib includes an axial connecting rod 13, a connecting rod angle positioning plate 12, and a set of upper and lower arc length adjustment beams 16; multiple axial connecting rods are fixedly connected between the arc length adjustment beams, and the connecting rod angle positioning plate is radially fixed by the multiple axial connecting rods; the power output end of the main hydraulic cylinder is hinged on the connecting rod angle positioning plate; the two ends of the arc length adjustment beam are respectively adjusted in arc length and axially offset to support the two arc surface templates.

[0035] Preferably, the arc length adjustment beam includes an arc-shaped square steel pipe 10 fixedly connected to both ends of the axial connecting rod, and an arc-shaped square steel column 9 slidably and telescopically inserted into the two arc ends of the arc-shaped square steel pipe; the free ends of the arc-shaped square steel column are radially penetrated and threadedly fixedly connected to radial screws 8, and the free ends of the radial screws are axially slidably adjusted to hang the arc surface template.

[0036] Preferably, multiple axial guide rails 7 are fixed on the side of the curved template facing the climbing formwork platform, and the free end of the radial screw is tensioned and fixed in the axial guide rail.

[0037] Preferably, pins 11 are axially connected to both ends of the arc-shaped square steel tube. The middle section of the pin extends into the interior of the arc-shaped square steel tube and is inserted and positioned on the arc-shaped square steel column to fix the arc-shaped square steel tube and the arc-shaped square steel columns at both ends in the arc length direction.

[0038] Preferably, the free end of the radial screw extends into the interior of the axial guide rail and is threadedly connected to a radial lock nut 14. The end face of the radial lock nut abuts against the inner wall of the axial guide rail to lock the free end of the radial screw axially and radially inside the axial guide rail.

[0039] In addition, in the preferred embodiment of the present invention, the hinged connection between the two ends of the main hydraulic cylinder and the radial slide and the connecting rod angle positioning plate is specifically a pin connection. Similarly, the hinged connection between the bottom of the frame back rib and the radial slide is also a pin connection. The main hydraulic cylinder provides power to provide pitch and tilt angle adjustment and tilt angle positioning functions for the multi-arc template. This pin connection method adopts mature technical means in the prior art.

[0040] In addition, preferably, the climbing formwork platform of the present invention adopts a mature product in the prior art, and the radial sliding table of the top radial sliding support of the climbing formwork platform is also a mature product in the prior art. The sliding connection between the two adopts a mature technical means in the prior art.

[0041] To more clearly illustrate the specific embodiments of the present invention, an example is provided below:

[0042] like Figure 1 As shown, one embodiment of the present invention includes a climbing formwork platform circumferentially distributed inside and outside the caisson. Multiple core-pulling-free climbing formwork units are arranged circumferentially along the platform. Each unit includes: a radial slide table that overlaps the climbing formwork platform via a prior art central axis guide rail slider mechanism. One radial end of the top surface of the radial slide table is hinged to the bottom end of the frame back rib, and the other radial end is hinged to the end of the cylinder body of the main hydraulic cylinder. The top end of the piston rod of the main hydraulic cylinder is hinged to a connecting rod angle positioning plate in the middle of the frame back rib.

[0043] The frame back brace consists of two parallel arc-length adjusting beams welded together as a single frame via several axial connecting rods. Angle positioning plates for the connecting rods are welded and fixed to the axial connecting rods. Each arc-length adjusting beam comprises an arc-shaped square steel tube and two arc-shaped square steel columns inserted from both ends. The arc-shaped square steel columns can be manually pulled out for adjustment and are fixed via pin holes and pins.

[0044] Each curved square steel column has a radial screw threaded through and connected to its free end. Two axial guide rails of different heights are welded to the back of each curved formwork panel. The free end of the radial screw is inserted into the axial guide rail, and the radial screw is clamped and fixed inside the axial guide rail by tightening the radial lock nut. After loosening the lock nut, the axial position of the curved formwork panel can be adjusted by sliding it, or the radial position of the curved formwork panel can be finely adjusted by rotating the radial screw. After adjustment, the lock nut is tightened again.

[0045] The joint edges of two adjacent curved templates are machined into sliding ramps that extend symmetrically from the midpoint. When the arc length needs to be increased, one template is slid to one side along the axial guide rail. Its ramp pushes aside the adjacent template, creating a misalignment between the two templates. This allows for stepless adjustment of the total arc length of the two adjacent curved templates during casting. Figure 7 As shown, the reverse operation reduces the arc length.

[0046] During construction, the formwork unit is first moved to the target radial position using a radial sliding platform. Then, the main hydraulic cylinder is activated to push the frame back ribs to the designed inclination angle. Next, the pouring arc length of the curved formwork is adjusted by pulling out the curved square steel column and inserting pins. Finally, the axial height difference between the two curved formwork panels is adjusted by sliding them in opposite directions, and the arc length is finely adjusted and closed using the sliding ramp. After adjustment, all moving parts are locked with pins and radial lock nuts, and concrete pouring can then proceed. After this layer is poured, the climbing formwork platform moves up one layer, and the above process is repeated for the subsequent hollow conical caisson concrete pouring from bottom to top (with the cone diameter gradually decreasing).

[0047] Finally, any aspects not fully described in this invention utilize existing mature products and technologies.

[0048] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A core-removing climbing formwork for cast-in-place construction of large-volume caissons in offshore wet docks, comprising a climbing formwork platform arranged circumferentially on the inner and outer circumferential surfaces of a hollow conical caisson, characterized in that: The climbing formwork also includes a radial slide, a main hydraulic cylinder, a frame back rib, and multiple curved templates. The radial slide slides horizontally and slides on the construction surface of the climbing formwork platform. One end of the main hydraulic cylinder and the bottom end of the frame back rib are hinged along the radial line connecting the top surface of the radial slide. The other end of the main hydraulic cylinder is hinged to support the top end of the frame back rib. The two ends of the frame back rib are respectively adjusted in arc length and axial offset to support the curved templates. The contact surface of two adjacent curved templates is made into a sliding inclined surface symmetrical about the center of the climbing formwork as the origin. The casting arc length of a single climbing formwork is adjusted by the axial offset difference between two adjacent curved templates.

2. The core-removing climbing formwork for cast-in-place construction of large-volume caissons in offshore wet docks according to claim 1, characterized in that: The frame back rib includes axial connecting rods, connecting rod angle positioning plates, and a set of upper and lower arc length adjustment beams; multiple axial connecting rods are fixedly connected between the arc length adjustment beams, and the connecting rod angle positioning plates are radially fixed by the multiple axial connecting rods; the power output end of the main hydraulic cylinder is hinged on the connecting rod angle positioning plate; the two ends of the arc length adjustment beams are respectively adjusted in arc length and axially offset to support the two arc surface templates.

3. The non-core-pulling climbing formwork for cast-in-place construction of large-volume caissons in offshore wet docks according to claim 2, characterized in that: The arc length adjustment beam includes an arc-shaped square steel pipe fixedly connected to both ends of an axial connecting rod, and an arc-shaped square steel column slidably and telescopically inserted into the two arc ends of the arc-shaped square steel pipe; the free ends of the arc-shaped square steel columns are radially penetrated and threadedly fixedly connected to radial screws, and the free ends of the radial screws are axially slidably adjusted to hang the arc surface template.

4. The non-core-pulling climbing formwork for cast-in-place construction of large-volume caissons in offshore wet docks according to claim 3, characterized in that: Multiple axial guide rails are fixed on the side of the arc-shaped template facing the climbing platform, and the free end of the radial screw is tensioned and fixed in the axial guide rail.

5. The non-core-pulling climbing formwork for cast-in-place construction of large-volume caissons in offshore wet docks according to claim 3, characterized in that: The two ends of the arc-shaped square steel tube are axially connected with pins. The middle section of the pins extends into the interior of the arc-shaped square steel tube and is inserted and positioned on the arc-shaped square steel column to fix the arc-shaped square steel tube and the arc-shaped square steel columns at both ends in the arc length direction.

6. The core-removing climbing formwork for cast-in-place construction of large-volume caissons in offshore wet docks according to claim 4, characterized in that: The free end of the radial screw extends into the axial guide rail and is threadedly connected to a radial lock nut. The end face of the radial lock nut abuts against the inner wall of the axial guide rail to lock the free end of the radial screw axially and radially inside the axial guide rail.

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