Prefabricated structure and method for caisson in dry dock

Abstract

The invention discloses a prefabricated structure and method for a caisson in a dry dock, and relates to the field of caissons in the dry dock. A middle ring wall assembly is arranged at the middle end of a bottom pouring base layer; a positioning column assembly is arranged on the outer side of the bottom pouring base layer, and an outer partition wall assembly is installed on the outer side of the positioning column assembly. According to the prefabricated structure and method for the caisson in the dry dock, the process of pouring the surface of the top layer of the caisson in the whole dry dock is achieved by firstly assembling the laminated slab assemblies along the upper ends of the outer partition wall assemblies and then pouring the surfaces of the assembled laminated slab assemblies after stable bearing and butt joint. The step-shaped inclined structure at the upper end of the positioning column assembly is matched for effective sealing pouring bearing treatment, integral pouring is achieved through the laminated slab assembly and the pouring layer, meanwhile, the technical effect of no construction joint is guaranteed, the defect that follow-up dismantling of traditional all-round scaffold bearing pouring is difficult and tedious is overcome, and the construction efficiency is improved. And in the process of top plate pouring, the supporting stability of the side is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of dry dock caisson technology, specifically to a prefabricated structure and method for dry dock caissons. Background Technology

[0002] Dry dock caissons float or sink by adjusting the ballast water in the tank. They are often used as foundations or wall components of hydraulic structures such as wharves and breakwaters. During the formation of the top plate of the dry dock caisson, a surface pouring operation is required.

[0003] For example, Chinese patent CN204898699U discloses a bridge caisson foundation, including a top slab, a caisson, and a bottom slab. The piers are placed on the top slab, and the bottom slab is placed on the bearing stratum. The caisson is a frame box structure with interconnected upper and lower parts composed of polygonal side plates. The bottom inner side of the polygonal side plates is sloped, and the cross-section is angular. The bottom slab and the bottom of the caisson, as well as the top slab and the top of the caisson, are cast in post-cast. Connecting steel bars are provided between the top slab and the bottom slab and the caisson. One or more caissons can be set. When multiple caissons are set, they are connected by connectors. This is more suitable for geological conditions where the bearing stratum is deep and weak and groundwater is abundant. Moreover, since the caisson is prefabricated in the factory, the construction quality can be guaranteed.

[0004] For example, Chinese patent CN118686214A discloses a method for on-site construction of large deep-water caissons. The method involves first casting the caisson bottom plate in a dry dock, then installing a double-walled steel cofferdam on the bottom plate, and then filling the dock with water to float and transport the bottom plate to the pier. The steel cofferdam is used as a temporary water-retaining structure, and the caisson is constructed using the on-site casting method. After the caisson is constructed, it is filled with water and sunk to its position. This method can significantly reduce the excavation depth requirement of the dry dock and reduce the dredging workload of the floating transport channel.

[0005] For example, Chinese patent CN102086647A discloses a caisson foundation, which includes a caisson body. The upper part of the caisson body is provided with a sand blowing port. The bottom plate of a large storage tank is fixed to the top plate of the caisson foundation, which is filled with sand with good flowability, by bolts. The horizontal position of the storage tank is adjusted by adjusting the sand in the caisson. If the storage tank tilts, sand can be sent in through the sand blowing port or sand can be extracted through the sand extraction port for adjustment. The method is simple and easy to implement, and is not affected by geological and weather conditions, thus ensuring the safe use of large storage tanks.

[0006] Most of the existing technologies mentioned above improve the overall structure. However, in the process of prefabrication of the top plate of the traditional dry dock caisson, a large amount of full-span scaffolding is required for support and assembly. The subsequent dismantling of the full-span scaffolding is difficult and cumbersome. During the pouring of the top plate, the stability of the side support cannot be guaranteed, which leads to certain limitations in its use. Summary of the Invention

[0007] The purpose of this invention is to provide a prefabricated structure and method for caissons in dry docks, in order to solve the problem mentioned in the background art that the top slab of traditional dry dock caissons requires a large amount of full-span scaffolding for support and assembly during the prefabrication process, and the subsequent dismantling of the full-span scaffolding is difficult and cumbersome, which leads to the inability to guarantee the stability of the side supports during the top slab pouring process.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A prefabricated structure for caissons in a dry dock includes a bottom cast-in-place base layer, a middle ring wall assembly at the middle of the bottom cast-in-place base layer, a positioning column assembly on the outer side of the bottom cast-in-place base layer, and an outer partition wall assembly installed on the outer side of the positioning column assembly. The outer end of the outer partition wall assembly is connected to the outer side of the middle ring wall assembly. A composite slab assembly is installed on the upper end of the outer partition wall assembly, and a pre-cast layer is formed on the surface of the composite slab assembly. An auxiliary locking structure is provided between the outer partition wall assembly and the composite slab assembly. The load-bearing and installation stability of the composite slab assembly is controlled by the auxiliary locking structure. The composite slab assembly and the cast-in-place layer are integrally cast, ensuring the technical effect of no construction joints.

[0010] Furthermore, the auxiliary locking structure is provided with a built-in reserved limiting member, which is threadedly installed inside the outer partition wall assembly. A reserved guide groove is provided on the inner side of the built-in reserved limiting member, and a movable nesting member is nested inside the reserved guide groove. An obliquely mating reserved member is fixedly connected to the upper end of the movable nesting member, and the obliquely mating reserved member corresponds to the inner position of the composite plate assembly.

[0011] Furthermore, the lower surface of the composite plate assembly is provided with a reserved inner groove, and the inner side of the reserved inner groove corresponds to the upper end position of the obliquely mating reserved part, and the reserved inner groove is evenly opened along the lower end of the composite plate assembly.

[0012] Furthermore, a transverse locking rubber component is nested on the inner and outer sides of the upper end of the built-in reserved limiting component, and a return spring is connected to the outer side of the transverse locking rubber component. The return spring is connected to the inner side of the built-in reserved limiting component, and the positions of the outer side of the transverse locking rubber component and the inner side of the reserved inner groove correspond to each other.

[0013] Furthermore, the positioning column assembly is distributed at an equal angle with respect to the center point of the bottom cast base, and the upper end of the positioning column assembly is in an inclined state. The upper end of the positioning column assembly abuts and fits against the lower end of the composite plate assembly. The composite plate assembly being assembled will apply pressure to the contacting inclined mating reserved part, so that it moves along the inner side of the built-in reserved limiting part in conjunction with the movable nesting part.

[0014] Furthermore, the built-in reserved limiting component is nested and connected with the composite plate assembly through the reserved inner groove, and the inclined docking reserved component and the movable nesting component inside the built-in reserved limiting component are pre-forced and nested and moved along the inner side of the reserved guide groove, and the upper end of the inclined docking reserved component has a frustum-shaped structure.

[0015] Furthermore, the lateral locking rubber components are symmetrically distributed about the center point of the built-in reserved limiting component, and the lateral locking rubber components form an elastic support structure along the inner side of the built-in reserved limiting component through the return spring. The contacting lateral locking rubber components are displaced laterally by applying force outward, so that the two sets of lateral locking rubber components are subjected to lateral auxiliary locking treatment along the inner end of the reserved inner groove, so as to avoid loosening or assembly gaps easily under stress.

[0016] Furthermore, as the inclined docking reserved part and the movable nesting part move downward along the inner side of the built-in reserved limiting part under the force, the upper end of the inclined docking reserved part, in conjunction with the frustum-shaped structure, applies force to the contacting transverse locking rubber part to cause transverse displacement.

[0017] Furthermore, a method for prefabricating caissons in a dry dock is provided, the specific steps of which are as follows:

[0018] S1. Bottom pouring base layer: The bottom pouring base layer is formed by pouring a large volume of concrete.

[0019] S2. Pouring of positioning column components: The positioning column components are poured along the outside of the bottom base layer. The formwork construction is carried out according to the construction range of the four tower cranes on the outer ring to ensure that the progress and workload of the four tower cranes are equal.

[0020] S3. Casting of the middle ring wall components: The middle ring wall components are cast sequentially along the bottom base surface;

[0021] S4. Casting of external partition wall components: Casting and shaping of external partition wall components along the middle ring wall components and positioning column components;

[0022] S5. Outer ring wall casting: The outer ring wall is cast and formed between the positioning column components;

[0023] S6. External Top Slab Pouring Sequence: Assemble the composite slab assembly along the upper end of the external partition wall assembly. After stable bearing and connection, pour the slab on the surface of the assembled composite slab assembly. Use the stepped inclined structure at the upper end of the positioning column assembly to effectively seal the pouring and bearing treatment. The composite slab assembly and the pouring layer are used to achieve integral pouring, and the technical effect of no construction joint is guaranteed.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] The caissons in this dry dock utilize prefabricated structures and methods. The process of pouring the top surface of the caisson in the dry dock involves first assembling composite slab components along the upper end of the outer partition wall components. After stable bearing and connection, pouring is then carried out on the surface of the assembled composite slab components. The stepped inclined structure at the upper end of the positioning column components provides effective sealing and bearing treatment during the pouring. The composite slab components and the pouring layer achieve integral pouring, ensuring the technical effect of no construction joints. This avoids the disadvantages of the subsequent difficult and cumbersome dismantling of traditional full-span scaffolding for bearing and pouring. During the pouring of the top slab, the stability of the side supports is guaranteed, ensuring the overall forming efficiency.

[0026] Furthermore, an auxiliary locking structure is provided to control the load-bearing installation stability of the composite slab assembly. During the assembly of the composite slab assembly along the upper end of the outer partition wall assembly, the pre-set built-in reserved limiting parts and the preliminary positioning guide structure of the reserved inner groove can quickly and accurately position and connect the composite slab assembly and the outer partition wall assembly. At the same time, the composite slab assembly being assembled will apply pressure to the contacting obliquely mating reserved parts, causing them to move along the inner side of the built-in reserved limiting parts in conjunction with the movable nesting parts. Thus, through the frustum-shaped structure at the upper end of the obliquely mating reserved parts, the contacting transverse locking rubber parts are displaced laterally outward, so that the two sets of transverse locking rubber parts are transversely locked along the inner end of the reserved inner groove, preventing them from easily loosening or assembly gaps under stress, thereby ensuring the stability and uniformity of the subsequent surface pouring of the composite slab assembly. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the three-dimensional structure of the bottom cast-in-place base layer of the present invention;

[0028] Figure 2 This is a three-dimensional structural diagram of the present invention;

[0029] Figure 3 This is a three-dimensional structural diagram of the positioning column assembly of the present invention;

[0030] Figure 4 This is a schematic diagram of the half-section three-dimensional structure of the built-in reserved limiting component of the present invention;

[0031] Figure 5 This is a three-dimensional structural diagram of the central wall component of the present invention;

[0032] Figure 6 This is a schematic diagram of the half-section three-dimensional structure of the oblique docking reserved part of the present invention;

[0033] Figure 7 This is a schematic diagram of the three-dimensional structure of the pre-cast layer of the present invention;

[0034] Figure 8This is a schematic diagram of the three-dimensional structure of the transverse locking rubber component of the present invention.

[0035] In the diagram: 1. Bottom pouring base layer; 2. Middle ring wall component; 3. Positioning column component; 4. External partition wall component; 5. Composite slab component; 6. Pre-cast pouring layer; 7. Built-in reserved limiting component; 8. Movable nesting component; 9. Angled docking reserved component; 10. Horizontal locking rubber component; 11. Return spring; 12. Reserved inner groove; 13. Reserved guide groove. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Example 1: Please refer to Figures 1-8 The present invention provides the following technical solution: a prefabricated structure and method for caissons in dry docks. In order to solve the problem that the top plate of the traditional dry dock caisson needs to be supported and assembled with a large amount of full-span scaffolding during the prefabrication process, and the subsequent dismantling of the full-span scaffolding is difficult and cumbersome, and the stability of the side support cannot be guaranteed during the pouring of the top plate, the present invention discloses that: a middle ring wall component 2 is provided in the middle of the bottom pouring base layer 1;

[0038] A positioning column assembly 3 is installed on the outer side of the bottom pouring base 1, and an outer partition wall assembly 4 is installed on the outer side of the positioning column assembly 3. The outer end of the outer partition wall assembly 4 is connected to the outer side of the middle ring wall assembly 2. A composite plate assembly 5 is installed on the upper end of the outer partition wall assembly 4, and a pre-cast layer 6 is formed on the surface of the composite plate assembly 5. An auxiliary locking structure is set between the outer partition wall assembly 4 and the composite plate assembly 5. The load-bearing installation stability of the composite plate assembly 5 is controlled by the auxiliary locking structure. The composite plate assembly 5 is assembled along the upper end of the outer partition wall assembly 4. After stable load-bearing connection, the surface of the assembled composite plate assembly 5 is then poured. With the step-shaped inclined structure at the upper end of the positioning column assembly 3, effective sealing and load-bearing treatment is achieved. The composite plate assembly 5 and the pouring layer achieve integral pouring, and the technical effect of no construction joint is guaranteed, avoiding the disadvantages of difficult and cumbersome subsequent dismantling of traditional full-span scaffolding load-bearing pouring.

[0039] Example 2: Based on Example 1, an auxiliary locking structure is also disclosed, which includes an auxiliary locking structure with a built-in reserved limiting member 7, and the built-in reserved limiting member 7 is threadedly installed inside the outer partition wall assembly 4;

[0040] The inner side of the built-in reserved limiting member 7 is provided with a reserved guide groove 13, and a movable nesting member 8 is nested inside the reserved guide groove 13. The upper end of the movable nesting member 8 is fixedly connected to an obliquely mating reserved member 9, and the obliquely mating reserved member 9 corresponds to the inner position of the composite plate assembly 5. The lower surface of the composite plate assembly 5 is provided with a reserved inner groove 12, and the inner side of the reserved inner groove 12 corresponds to the upper position of the obliquely mating reserved member 9. The reserved inner groove 12 is evenly opened along the lower end of the composite plate assembly 5. The upper inner and outer sides of the built-in reserved limiting member 7 are nested with a transverse locking rubber member 10, and the outer side of the transverse locking rubber member 10 is mated with a return spring 11. Furthermore, the return spring 11 and the inner side of the built-in reserved limiting member 7 are connected to each other, the outer side of the transverse locking rubber member 10 and the inner side of the reserved inner groove 12 are positioned to correspond to each other, the positioning column assembly 3 is distributed at equal angles about the center point of the bottom cast base 1, and the upper end of the positioning column assembly 3 is in an inclined state structure, and the upper end of the positioning column assembly 3 is in contact and fits with the lower end of the composite plate assembly 5. The built-in reserved limiting member 7 is nested and connected with the composite plate assembly 5 through the reserved inner groove 12, and the inclined docking reserved member 9 and the movable nesting member 8 on the inner side of the built-in reserved limiting member 7 are pre-forced and nested and moved along the inner side of the reserved guide groove 13, and the upper end of the inclined docking reserved member 9 is in a frustum-shaped structure.

[0041] The lateral locking rubber parts 10 are symmetrically distributed about the center point of the built-in reserved limiting part 7, and the lateral locking rubber parts 10 form an elastic support structure along the inner side of the built-in reserved limiting part 7 through the return spring 11. During the process of the oblique docking reserved part 9 and the movable nesting part 8 moving downward along the inner side of the built-in reserved limiting part 7 under force, the upper end of the oblique docking reserved part 9 cooperates with the frustum-shaped structure to exert a force on the contacting lateral locking rubber parts 10 to displace laterally. During the process of assembling the composite plate assembly 5 along the upper end of the outer partition wall assembly 4, the initial movement of the pre-set built-in reserved limiting part 7 and the reserved inner groove 12 is achieved. The positioning and guiding structure allows for quick and precise positioning and assembly of the composite panel assembly 5 and the external partition wall assembly 4. Simultaneously, the composite panel assembly 5, during assembly and assembly, applies pressure to the contacting obliquely mating reserved parts 9, causing them to move along the inner side of the built-in reserved limiting parts 7 in conjunction with the movable nesting parts 8. Through the frustum-shaped structure at the upper end of the obliquely mating reserved parts 9, the contacting transverse locking rubber parts 10 are displaced laterally outward, allowing the two sets of transverse locking rubber parts 10 to be transversely locked along the inner end of the reserved inner groove 12, preventing them from easily loosening or creating assembly gaps under stress.

[0042] Example 3: Based on Examples 1 and 2, a method for forming a prefabricated structure is also disclosed, including the following steps:

[0043] S1. Bottom pouring base layer 1 pouring: The bottom pouring base layer 1 is formed by pouring a large volume of concrete.

[0044] S2, Pouring of Positioning Column Assembly 3: The positioning column assembly 3 is poured along the outside of the bottom pouring base layer 1. The formwork construction is carried out according to the construction range of the four tower cranes in the outer ring to ensure that the progress and workload of the four tower cranes are equal.

[0045] S3, Casting of the middle ring wall component 2: The middle ring wall component 2 is cast sequentially along the surface of the bottom casting base 1 around its circumference;

[0046] S4, Casting of outer partition wall component 4: Casting of outer partition wall component 4 is carried out between the middle wall component 2 and the positioning column component 3;

[0047] S5. Outer ring wall casting: The outer ring wall is cast and formed between the positioning column components 3;

[0048] S6. External top slab pouring sequence: Assemble the composite slab assembly 5 along the upper end of the external partition wall assembly 4. After stable bearing and connection, pouring work is carried out on the surface of the assembled composite slab assembly 5. Effective sealing and bearing treatment is carried out in conjunction with the stepped inclined structure at the upper end of the positioning column assembly 3. The composite slab assembly 5 and the pouring layer are used to achieve overall pouring.

[0049] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" 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. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0050] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A prefabricated structure for a caisson in a dry dock, comprising a bottom cast-in-place base layer (1), wherein a central wall assembly (2) is provided at the middle end of the bottom cast-in-place base layer (1), characterized in that: A positioning column assembly (3) is provided on the outer side of the bottom cast base (1), and an outer partition wall assembly (4) is installed on the outer side of the positioning column assembly (3). The outer end of the outer partition wall assembly (4) is connected to the outer side of the middle ring wall assembly (2). A composite plate assembly (5) is installed on the upper end of the outer partition wall assembly (4), and a pre-cast layer (6) is formed on the surface of the composite plate assembly (5). An auxiliary locking structure is provided between the outer partition wall assembly (4) and the composite plate assembly (5). The load-bearing installation stability of the composite plate assembly (5) is controlled by the auxiliary locking structure.

2. The prefabricated structure for caissons in a dry dock according to claim 1, characterized in that: The auxiliary locking structure is provided with a built-in reserved limiting member (7), and the built-in reserved limiting member (7) is threadedly installed inside the outer partition wall assembly (4). A reserved guide groove (13) is opened on the inner side of the built-in reserved limiting member (7), and a movable nesting member (8) is nested on the inner side of the reserved guide groove (13). An oblique docking reserved member (9) is fixedly connected to the upper end of the movable nesting member (8), and the oblique docking reserved member (9) corresponds to the inner position of the composite plate assembly (5).

3. The prefabricated structure for caissons in a dry dock according to claim 2, characterized in that: The lower surface of the composite plate assembly (5) is provided with a reserved inner groove (12), and the inner side of the reserved inner groove (12) corresponds to the upper end position of the obliquely mating reserved part (9), and the reserved inner groove (12) is evenly opened along the lower end of the composite plate assembly (5).

4. The prefabricated structure for caissons in a dry dock according to claim 3, characterized in that: The upper end of the built-in reserved limiting member (7) is nested with a transverse locking rubber member (10) on the inner and outer sides, and the outer side of the transverse locking rubber member (10) is connected to a reset spring (11), and the reset spring (11) is connected to the inner side of the built-in reserved limiting member (7). The outer side of the transverse locking rubber member (10) and the inner side of the reserved inner groove (12) are in corresponding positions.

5. A prefabricated structure for caissons in a dry dock according to claim 4, characterized in that: The positioning column assembly (3) is distributed at equal angles with respect to the center point of the bottom cast base (1), and the upper end of the positioning column assembly (3) is in an inclined state structure, and the upper end of the positioning column assembly (3) is in contact with and fits against the lower end of the composite plate assembly (5).

6. A prefabricated structure for caissons in a dry dock according to claim 5, characterized in that: The built-in reserved limiting member (7) is nested and connected with the composite plate assembly (5) through the reserved inner groove (12), and the inclined docking reserved member (9) and the movable nesting member (8) inside the built-in reserved limiting member (7) are pre-forced and nested along the inner side of the reserved guide groove (13), and the upper end of the inclined docking reserved member (9) has a frustum-shaped structure.

7. A prefabricated structure for caissons in a dry dock according to claim 6, characterized in that: The transverse locking rubber component (10) is symmetrically distributed about the center point of the built-in reserved limiting component (7), and the transverse locking rubber component (10) forms an elastic support structure along the inner side of the built-in reserved limiting component (7) through the return spring (11).

8. A prefabricated structure for caissons in a dry dock according to claim 7, characterized in that: As the inclined docking reserved part (9) and the movable nesting part (8) are subjected to force and move downward along the inner side of the built-in reserved limiting part (7), the upper end of the inclined docking reserved part (9) cooperates with the frustum-shaped structure to exert force on the contacting transverse locking rubber part (10) to displace laterally.

9. A method for forming a prefabricated structure for a caisson in a dry dock, applicable to the prefabricated structure for a caisson in a dry dock as described in any one of claims 1-8, characterized in that, The specific steps of this method are as follows: S1, Bottom pouring of base layer (1) Pouring: The bottom base layer (1) is formed by pouring large volume concrete. S2, Pouring of the positioning column assembly (3): The positioning column assembly (3) is poured along the outside of the bottom pouring base (1). The formwork construction is carried out according to the construction range of the four tower cranes in the outer ring to ensure that the progress and workload of the four tower cranes are comparable. S3, Middle Ring Wall Components (2) Casting: The middle wall component (2) is cast sequentially along the bottom base layer (1) surface; S4, External partition wall components (4) pouring: The outer partition wall assembly (4) is cast and formed between the middle wall assembly (2) and the positioning column assembly (3); S5. Outer ring wall pouring: The outer ring wall is cast between the positioning column assemblies (3); S6. Pouring sequence of the outer top slab: Assemble the composite plate assembly (5) along the upper end of the outer partition wall assembly (4), and after stable bearing and connection, pour the concrete on the surface of the assembled composite plate assembly (5). Combined with the stepped inclined structure at the upper end of the positioning column assembly (3), perform effective sealing and pouring bearing treatment. The composite plate assembly (5) and the pouring layer achieve overall pouring, and the technical effect of no construction joint is guaranteed.

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